Technician’s Guide

Automatic Transmission Fluid

Understanding/Analysis

GN2055EN
 TRADEMARK INFORMATION
DEXRON® is a registered trademark of General Motors Corporation.
TranSynd™ is a trademark of Castrol Ltd.

Copyright 2001 General Motors Corporation

AU T O M A T I C TR A N S M I S S I O N F L U I D — TE C H N I C I A N ’S G U I D E

TABLE OF CONTENTS

Page No.
LIST OF FIGURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
LIST OF TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
THE FUNCTIONS OF AN AUTOMATIC TRANSMISSION FLUID . . . . . . . . . . . . . . . . . . 4
Operating Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Functions and Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
HOW AN AUTOMATIC TRANSMISSION FLUID MEETS ITS DEMANDS . . . . . . . . . . . . 5
Viscosity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Incompressibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Oxidation/Corrosion Inhibition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
WHY AN AUTOMATIC TRANSMISSION FLUID FAILS TO MEET
ITS DEMANDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Viscosity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Oxidation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Contamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
MEASUREMENT OF IMPORTANT FLUID CHARACTERISTICS
AND REACTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Viscosity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Infrared (IR) Scan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Total Acid Number (TAN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Solids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Emission Spectroscopy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Other Particle/Wear Metal Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
DESIGNING A FLUID ANALYSIS PROGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Sampling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Test Selection and Utilization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
FLUID SELECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Recommended Fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Other Fluids and Additives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
FLUID STORAGE AND HANDLING PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Storing and Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Health Issues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
SUMMARY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
COMMON MISCONCEPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
DEFINITION OF TERMS AND ABBREVIATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
FOOTNOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

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LIST OF FIGURES

Page No.

Figure 1. ASTM Standard Viscosity/Temperature Chart . . . . . . . . . . . . . . . . . . . . . . 6

Figure 2. Viscosity Index Improver Shear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Figure 3. Viscosity Increase with Oxidation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Figure 4. Resultant Viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Figure 5. Differential Infrared (IR) Scan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Figure 6. Spectrograph Analysis Technique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Figure 7. Spectrograph Detection Effectivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Figure 8. Particle Detection Comparison. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Figure 9. Sample Trendline Plot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

LIST OF TABLES

Page No.

Table 1. Infrared (IR) Scan Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Table 2. Sampling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Table 3. Fluid Oxidation Measurement Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Table 4. Contaminant Limits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Table 5. Sources of Wear Metals and ATF Analysis Elements . . . . . . . . . . . . . . . . 16
Table 6. Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Table 7. Common Misconceptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

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 AU T O M A T I C TR A N S M I S S I O N F L U I D — TE C H N I C I A N ’S G U I D E
INTRODUCTION
Oil Analysis is the key to understanding how the trans-
mission fluid in your Allison automatic transmission
responds to daily operations. Oil analysis coupled with
regularly scheduled transmission fluid and filter mainte-
nance decreases the likelihood of experiencing down-
time caused by serious transmission problems or failure.
Transmission fluid analysis makes it possible to set
fluid change intervals more accurately. Operating
loads, speeds, ambient temperature, number of shifts,
and retarder usage all have an effect on transmission
fluid. Understanding these changes are critical to
establishing proper fluid change intervals.
This booklet is intended to expand the user’s
knowledge of fluids and their analysis and offer
* Footnotes are located on page 25 at the end of this Guide.
guidelines on their use. Specifically, it addresses the
basic characteristics and reactions of fluids, provides
understanding of some standard laboratory test
procedures accepted throughout the industry, and
provides guidance in interpreting and using the results.
Allison Transmission now offers a user friendly Oil
Analysis Kit (P/N 29537805) to assist Allison
customers in conducting fluid analysis.
Contact your nearest Allison distributor/dealer for pric-
ing and availability of all Allison products. Locate your
Allison distributor/dealer on the internet at
www.allisontransmission.com.
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 AU T O M A T I C TR A N S M I S S I O N F L U I D — TE C H N I C I A N ’S G U I D E
THE FUNCTIONS OF AN
AUTOMATIC TRANSMISSION FLUID
OPERATING ENVIRONMENT
Understanding the environment an Automatic
Transmission Fluid (ATF) is subjected to is essential in
discussing its function and requirements.
The environment in which an ATF is expected to oper-
ate is anything but mild. The transmission is typically
placed in the same vehicle cavity as the engine and
radiator and subject to whatever temperature is
present. Further, the transmission cooling function is
dependent on the temperature of the engine coolant
for heat dissipation and any engine overheat results in
transmission overheat. Air flow in this compartment is
usually marginal. Dust and road contaminants are a
part of this environment as well and some of it is
ingested through the transmission breather. While in
this environment, the transmission must transmit
power from the engine to the drive axle. Consequently,
the fluid in the transmission must perform a variety of
functions to meet all of its requirements.
FUNCTIONS AND REQUIREMENTS
The fluid in an automatic transmission must per-
form many important functions beyond that of
basic lubrication.
While lubrication is important, the fluid must first pro-
vide drive through the torque converter, supply logic
pressure to the range control system and then supply
hydraulic pressure that causes a clutch pack to
engage. An engine will run, at least briefly, without its
lubricating oil, but an automatic transmission will not
function at all without its transmission fluid. Fluids used
in Allison automatic transmissions must perform sev-
eral distinct functions. These are:
• Hydrodynamic energy transmission medium for
use in the torque converter.
• Hydrostatic energy transmission medium for use in
the hydraulic control logic circuits and for servo-
mechanisms.
• Lubricating medium for shaft bearings, thrust bear-
ings, and involute or spur gear load surfaces.
• Sliding friction energy transmission medium for
use with lubricated clutches.
4
• Heat transfer medium with liquid or air-cooled sys-
tems for maintenance of a suitable automatic
transmission temperature range.1
• Further maintain acceptable heat levels by over-
coming friction between moving parts. When a
layer of fluid separates two moving components,
fluid friction replaces the much stronger dry fric-
tion.
• Absorb shock loads produced by variations in load
and drive, engine torsional activity or vibration,
shifting, and wheel slip. Even the impact caused
by the meshing of gears — particularly on start-up
— is softened to a large extent by the fluid trapped
between the teeth of the gears.2
• Improve the ability of seals to maintain hydraulic
pressure by acting as a sealant.
In addition to these basic functions, other important
requirements achieved through the use of additives
include:
• Operate satisfactorily over a wide temperature
range; i.e., provide startability and essential lubri-
cating flow at low temperature while maintaining its
lubrication qualities and fluid film thickness at high
temperatures.
• Be compatible with a variety of seal materials.
• Contain or keep in suspension contaminants intro-
duced into or generated in the transmission, and
thereby maintain transmission cleanliness.
• Resist oxidation and the fluid thickening it causes.
• Reduce friction beyond normal lubrication through
the use of friction modifiers for reduced internal
wear and improved operating efficiency.
• Minimize fluid foaming which reduces fluid film
thickness and clutch-apply pressure.
• Be non-corrosive towards all transmission compo-
nents and furthermore, inhibit corrosion of compo-
nents from other sources by forming a protective
layer.
These functions and requirements constitute quite a
list of demands and one might doubt the ability of any
fluid to meet them all. Today’s fluids are the result of
years of experience and research. Lubrication scien-
tists have developed both the refinement processes
and subsequent additives to such an extent that the
resultant fluids effectively address the demands placed
on them.
 AU T O M A T I C TR A N S M I S S I O N F L U I D — TE C H N I C I A N ’S G U I D E
HOW AN AUTOMATIC TRANSMISSION FLUID
MEETS ITS DEMANDS
A fluid’s ability to meet demands placed on it depends
entirely on its physical and chemical properties which
can either be inherent or induced through the use of
additives. The properties or characteristics selected for
discussion are viscosity, incompressibility, and oxida-
tion inhibition.
VISCOSITY
Viscosity is one of the most important and most
evident properties of a fluid, and is defined as its
resistance to flow, recognizable by its thickness.
Viscosity can be further defined as the resistance
(fluid friction) of one layer of fluid to movement while
another layer in contact with it remains fixed. This
resistance increases as viscosity increases. Thus,
increasing viscosity leads to decreasing energy trans-
mission efficiency. Yet, decreasing viscosity can lead
to a fluid whose resistance to flow is so low that the
film boundary between mating components is actually
squeezed out allowing the components to contact.
Obviously, a delicate balance must be achieved and
then maintained throughout operation.
Another operating difficulty with the property of vis-
cosity is its reaction to temperature. Most fluids are
more viscous at reduced temperatures and less vis-
cous at elevated temperatures. Because of the prob-
lems associated with extreme viscosities, high or low,
a distinct need exists for a fluid of a more tempera-
ture-stable viscosity resulting in the development of
“multi-viscous” fluids. Thus, two types of fluids are
produced: straight-grade fluid and multi-viscous fluid.
Most fluids become thinner at elevated temperatures
but a multi-viscous fluid will thin at a reduced rate
compared to straight-grade fluid. An SAE 30 weight
fluid behaves as a 30 weight fluid at all temperatures
while a multi-viscous fluid, i.e., SAE 15W40, behaves
as an SAE 15 weight fluid at low temperatures and as
an SAE 40 weight fluid at elevated temperatures.
Figure 1 illustrates the relationship of viscosity to
temperature and the behavior of a straight-grade ver-
sus a multi-viscous fluid. The chart is valid between
the temperatures at which the viscosities were mea-
sured (100–210°F; 38–99°C). It is customary to
project the plotted data as shown. However, some
deviation from the linear (negative slope) should be
expected around the cloud point of the lubricant.
Cloud point refers to the temperature at which wax
crystals materialize in the fluid, 0–30°F (-18 to -1°C)
for most transmission fluids.
The “variable” viscosity characteristic is obtained by
additives called Viscosity Index (VI) Improvers.
VI Improvers are best described as oil-soluble
organic polymer chains that are temperature sensi-
tive. They are tightly coiled at low temperatures and
have little or no effect on viscosity. As temperature
increases, however, these chains begin to lengthen,
uncoil and interact with each other. It is their length
and interaction that causes the thickening effect or
viscosity increase over the inherent viscosity present
in the base stock. The first number listed in a multi-
grade notation is essentially the viscosity of the base
stock and the second number is the grade achieved
at elevated temperature by the use of VI Improvers.
VI Improvers theoretically increase the viscosity at all
temperatures, but it becomes considerably more pro-
nounced as temperature increases. The amount and
configuration of the VI Improver used determines the
differential between the two grades.
INCOMPRESSIBILITY
The incompressibility of a fluid is a property that is
often overlooked since all liquids are basically incom-
pressible. But this property is essential. Incompress-
ibility allows a fluid to efficiently transmit power
through the torque converter and transfer pressure to
the controls, clutches and lubrication points. This
property is inherent and is only affected when air bub-
bles are introduced. Since air is compressible, a fluid
contaminated with air bubbles compresses and does
not transmit full pressure.
The additives used to help control air content in the
fluid are referred to as anti-foam agents. These chem-
icals control air bubbles by reducing the surface ten-
sion of the fluid allowing the air bubbles to break
through the fluid surface.
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 AU T O M A T I C TR A N S M I S S I O N F L U I D — TE C H N I C I A N ’S G U I D E

HOW AN AUTOMATIC TRANSMISSION FLUID

MEETS ITS DEMANDS (cont’d)

100 000
50 000 FOR LIQUID PETROLEUM PRODUCTS (D 341)
20 000 CHART B: SAYBOLT UNIVERSAL
10 000 VISCOSITY. ABRIDGED
100°F 210°F
5000
(38°C) (99°C)
VISCOSITY, SAYBOLT UNIVERSAL SECONDS

2000 SAE 30 550 68

SAE 40 1090 78
1000 15W-40 460 76
750
500
400
300
200
150

100
90
80
70
60
55
50
45

40

35

–30 –20 –10 0 10 20 30 40 50 60 70 80 90 110 130 150 175 200 225 250 275 300 325 350
°F 100 120 140 °F

–35 –25 –15 –5 0 5 10 15 20 30 40 50 60 70 80 90 100 115 130 145 160 175

°C –30 –20 –10 25 35 45 °C
TEMPERATURE V01803

Figure 1. ASTM Standard Viscosity/Temperature Chart

OXIDATION/CORROSION INHIBITION coating also provides protection from corrosive sub-

Oxidation, by general definition, is the combination or
chemical reaction of a substance with oxygen. The
presence of water and heat accelerate the reaction.
Lubricating fluids naturally coat a surface with a pro-
tective film which displaces any oxygen or water
present and thus prevents oxidation of the metals. The
stances that might be present. The fluid is assisted by
additives already mentioned, additives that actually
react with or plate onto metal surfaces forming a pro-
tective barrier, as well as additives that neutralize acids
within the fluid. Equally important is the inherent oxida-
tion resistance of the fluid, controlled by base stock
selection, refining, and additives.

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 AU T O M A T I C TR A N S M I S S I O N F L U I D — TE C H N I C I A N ’S G U I D E
WHY AN AUTOMATIC TRANSMISSION FLUID
FAILS TO MEET ITS DEMANDS
During normal operation, an ATF does react to both
the environment and the demands placed on it. Oxy-
gen, heat, wear particles, and severe usage directly
affect fluid characteristics.
VISCOSITY
Viscosity is typically the first property to experience a
measurable change during operation. The VI Improv-
ers are added to improve the temperature viscosity
property of the fluid. Since they are long polymer
chains of high molecular weight, they are less stable
chemically and susceptible to “sheardown.” Shear-
down is a function of time and severity of operation. It
occurs when a polymer chain passes through a low
clearance, high stress meshing interface (planetary
gears, main-pressure pump, clutch plates, torque con-
verter, etc.) where the chains are actually cut or
sheared into smaller pieces. This sheardown typically
begins to reduce the elevated temperature viscosity
almost immediately and will continue to do so, though
at a decreasing rate throughout the life of a fluid until it
reaches the viscosity of the base stock. Figure 2 illus-
trates the viscosity change due to VI Improver shear.
Straight-grade fluids do not have VI Improver additives
and do not experience viscosity reductions due to
shear.
VISCOSITY
VI IMPROVER SHEAR ✽
BASE STOCK VISCOSITY
TIME/TEMPERATURE
✽ Not Applicable for Straight-Grade Fluids
Figure 2. Viscosity Index Improver Shear
OXIDATION
Oxidation is probably the single most deciding fac-
tor in limiting the functional life of a fluid.
Fluid oxidation is a chemical reaction between the fluid
and oxygen much like rust is a chemical reaction
between iron and oxygen. Both reactions create a
product, oxidized fluid and iron oxide respectively, that
has little or no ability to perform the original function.
The speed of the reaction depends on several environ-
mental conditions: air mix, temperature, time, and cat-
alysts. Oxidation literally means “a reaction with
oxygen.” It follows that increased exposure to air pro-
vides increased opportunity to oxidize and the pres-
ence of an air supply is the most significant contributor
to oxidation. The next significant contributor to oxida-
tion is temperature; fluid oxidation rate increases as
temperature increases. It is because of both conditions
that transmission overfill can be so harmful. If a trans-
mission is overfull, the fluid level reaches the rotating
parts of the transmission. This contact results in
“churning” which aerates and heats the fluid, thus
accelerating oxidation. The last noteworthy contributor
to oxidation is the presence of catalyst metals such as
iron and copper.
Oxidation has a serious and lasting effect on any
petroleum product, and transmission fluid is no excep-
tion. Oxidation creates chemical changes causing
acidity and solid matter to form and an increase in vis-
cosity, all of which can be measured. The sludge and
solid matter formed from the fluid oxidation, as well as
additive oxidation or depletion and dispersant satura-
tion, are primarily responsible for the increase in vis-
cosity that is usually characteristic of advanced
oxidation. The increase in viscosity is represented in
Figure 3.
Recall that multi-viscous fluids can experience viscos-
ity reduction due to sheardown. Figure 4 illustrates the
resultant viscosity when both sheardown and oxidation
are present. A straight-grade fluid would only experi-
ence oxidation.
V01804
Oxidation resistance is controlled in part by base stock
selection and preparation, but additional resistance is
typically needed. The additional resistance is obtained
through the use of additives. Assorted additives are
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 AU T O M A T I C TR A N S M I S S I O N F L U I D — TE C H N I C I A N ’S G U I D E

WHY AN AUTOMATIC TRANSMISSION FLUID

FAILS TO MEET ITS DEMANDS (cont’d)

available to improve the oxidation resistance of a fluid.

One already mentioned is an anti-foam agent intended
to reduce the presence of air bubbles in a fluid. This
reduces oxidation by reducing the surface contact of
the fluid with air. Other additives are anti-oxidants.
These additives work on a molecular scale by sacrific-

VISCOSITY
ing themselves to the oxidation process thus limiting or OXIDATION INCREASE
controlling oxidative breakdown of the fluid. Synthetic
fluids have a more stable molecular structure naturally
because of their specialized, controlled manufacture or
“synthesis.” However, the same additive types are still
used in synthetic blends to achieve maximum oxidation
resistance. BASE STOCK VISCOSITY

CONTAMINATION TIME/TEMPERATURE

V01805
Contamination is the remaining major hindrance to
fluid efficiency and can originate from a variety of
sources, those most notable being oxidation, environ- Figure 3. Viscosity Increase With Oxidation
ment, and component wear. As stated, oxidation cre-
ates acidity and solid matter, both of which must be
addressed to maintain fluid and transmission life. Acid-
ity is usually addressed by introducing alkaline addi-
tives to the base stock. Fortunately, in an automatic
transmission, the fluid seldom becomes very acidic
unless allowed to severely oxidize. Consequently, ATF
seldom contains high concentrations of alkaline addi-
tives. Nonetheless, increasing acidity in a transmission
is important and should be part of a fluid analysis pro-
VISCOSITY

gram. RESULTANT

The solid matter by-product of oxidation, if left alone,

OXIDATION SHEARDOWN
deposits onto surfaces throughout the transmission. EFFECT EFFECT ✽
This contaminant, as well as limited contaminants from
external sources, are counteracted by detergents and BASE STOCK VISCOSITY
dispersants. Detergents maintain surface cleanliness
while dispersants keep contaminants in suspension.
Contaminant suspension is necessary to provide for TIME/TEMPERATURE
effective fluid changes; only those contaminants sus- ✽ Not Applicable for Straight-Grade Fluids
V01806
pended in the fluid are removed during drainage.
These additives are essential in maintaining cleanli-
ness and achieving expected fluid life. Figure 4. Resultant Viscosity

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 AU T O M A T I C TR A N S M I S S I O N F L U I D — TE C H N I C I A N ’S G U I D E
MEASUREMENT OF IMPORTANT FLUID
CHARACTERISTICS AND REACTIONS
Effective analysis of fluids requires an ability to mea-
sure the various fluid characteristics. There are hun-
dreds of different tests that can be used to evaluate
lubricants, hydraulic fluids, and other oils. Often, two or
three different tests can be used to measure the same
characteristics. These similar tests vary in cost, accu-
racy, and the time required to complete each test.3
In the interest of standardizing testing, the American
Society for Testing and Materials, ASTM, has devel-
oped a full spectrum of tests that have been widely
accepted. These standardized tests provide increased
accuracy and reliability between labs. However, some
variation still exists between labs.
VISCOSITY
Fluid viscosity is most often measured by ASTM Stan-
dard D445. This procedure measures the time required
for a given volume of fluid to pass through a specific
size orifice at a given temperature. It is typically mea-
sured at 104°F (40°C) and at 212°F (100°C). The ori-
ficed tube assembly is immersed in a liquid bath with
the bath temperature maintained at each given value.
This procedure is accurate within 0.5 percent.
Viscosity can also be measured by a falling ball com-
parator. This is a portable test that can be performed
quickly on-site with reasonable accuracy. This method
compares the sample fluid to a previously calibrated
reference fluid. Identical balls are allowed to fall freely
through the reference and sample fluids. The relative
distance each ball falls is used by comparison to deter-
mine the sample fluid viscosity. The accuracy of this
method varies between 1 and 5 percent, depending on
user experience. Obviously, the ball may be difficult to
see in dark fluids or fluids that are badly oxidized, limit-
ing the application of this procedure.
INFRARED (IR) SCAN
An IR scan is most often obtained by differential
analysis. This procedure basically measures the
differential between the amount of IR light absorbed by
a used fluid sample and a reference (new) sample. It
involves an IR light source inside an opaque box that is
directed simultaneously through the used and new
fluid samples as shown in Figure 5. Pocketed cells
control the thickness of the fluid samples. After
passing through the fluid samples, the IR light is
reflected through a rotating chopper and into a
detector where it is analyzed. The rotating chopper
alternately blocks one of the two signals so the
detector is only receiving one signal at any given time.
The analyzer compares the signals from the new fluid
to that of the used fluid and reports the difference as
absorbance units per centimeter of fluid thickness. IR
light at various wavelengths (in microns) may be used
and the amount of light absorbed at each wavelength
can reveal information about water, glycol, minerals,
organic acids (oxidation), synthetic additives, and
nitrates, as shown in Table 1. This procedure is
accurate within approximately 1/100th of an
absorbance unit.4
REFERENCE SAMPLE
(NEW FLUID)
DETECTOR
REFLECTING
MIRRORS
IR LIGHT
SOURCE
ROTATING
CHOPPER TESTED SAMPLE
(USED FLUID)
V01807
Figure 5. Differential Infrared (IR) Scan
9
 AU T O M A T I C TR A N S M I S S I O N F L U I D — TE C H N I C I A N ’S G U I D E

MEASUREMENT OF IMPORTANT FLUID

CHARACTERISTICS AND REACTIONS (cont’d)

Table 1. Infrared (IR) Scan Results WATER

WAVELENGTH Two ASTM tests, Standards D95 and D1744, are used
RESULTS/INDICATIONS
(MICRONS) for water content measurement. The first, Standard
D95, is used for gross water contamination with the
2.9 Water, Glycol result expressed in volume percent. The water content
is determined by distillation and accurate within 2 per-
3.5* Hydrocarbon (Indicates Minerals)
cent. The second test, Standard D1744, determines
5.8* Carbonyl, Carboxylic, Organic water content by reacting the sample with a karl fisher
Acids (Indicates Oxidation and reagent and is useful for determining contamination of
Synthetic Additives) small amounts of water (1000 ppm). Results are
expressed in parts-per-million (ppm) and accurate
6.1 Nitrate (NOx) within 10 percent.

9.6 Glycol
EMISSION SPECTROSCOPY
* A major change in the ratio of the readings at 3.5 and 5.8 wavelengths
indicates a significant change in base stock (brake fluid, etc., added by
mistake). Spectrographic analysis is done by a very specialized
instrument that burns a small sample of the fluid
between two electrodes as shown in Figure 6.
TOTAL ACID NUMBER (TAN)
Advanced oxidation will always be accompanied by the
presence of acid. This acid is best measured by adding
an indicator solution to a fluid sample and then adding
potassium hydroxide (KOH) until the solution changes
color. The acidity is expressed as the milligrams of
KOH required to neutralize a gram of fluid. The stan- UPPER
dard for this procedure is ASTM Standard D974 and is ELECTRODE
accurate within 15 percent. If the fluid is too dark to (ROD)
use a color indicator, the change in electrical conduc-
tivity can be measured as the KOH is added. The stan-
dard for this procedure is ASTM Standard D664 and is LOWER
ELECTRODE SPARK
accurate within 4 percent.
(DISC)
FLUID
SOLIDS
TRAY
Solid matter is another indication of oxidation and is
simply solid particles suspended in the fluid. It is best
measured by centrifuging a fluid sample at a given
RPM in a tube that is narrowed and graduated at the V01808
bottom. The solids collect in the bottom and can be
measured in percent by volume. The standard for this
procedure is ASTM Standard D91. Figure 6. Spectrograph Analysis Technique

10
 AU T O M A T I C TR A N S M I S S I O N F L U I D — TE C H N I C I A N ’S G U I D E
MEASUREMENT OF IMPORTANT FLUID
CHARACTERISTICS AND REACTIONS (cont’d)
The lower disk electrode rotates with the lower half of
the disk submerged in the fluid. As it rotates, a thin
coating of fluid is carried up between the two elec-
trodes where it is burned to a vapor. During the burn-
ing process, atoms of a given element are excited by
energy absorption to the point of actually releasing
electrons. As soon as the vaporized element passes
out of the electric field, the electrons are recaptured by
the atom and they give off, as light, the energy they
absorbed in the separation. This light or energy and its
wavelength varies with each element. Thus, the ele-
ment present can be identified by the wavelength of
the light emitted. The efficiency of this process is
dependent on particle size as graphed in Figure 7.
100
EFFICIENCY — %
50
0 blocked or reflected, and how much passes through to
5 10 15 40 50 60 100
PARTICLE SIZE (MICRONS)
Figure 7. Spectrograph Detection Effectivity
Particles larger than seven microns are very difficult for
a spectrograph instrument to accurately detect, and
particles larger than ten microns may not be detected
at all. Anything larger is either not picked up by the
rotating lower electrode or is not vaporized completely.
(For relative comparison, the human eye, at best under
ideal conditions, can see particles no smaller than 40
microns.) Spectrograph results are typically given in
parts per millions (ppm).
OTHER PARTICLE/WEAR METAL
MEASUREMENTS
• Particle Count, Visual
In this procedure, a small amount of fluid (usually
100 ml) is passed through a standard filter disk. The
disk is examined under a microscope, and the parti-
cles of different size ranges are counted manually. The
results are expressed as the number of particles in a
particular size range, such as 180,000 per 100 ml in
the 5–15 micron range.
The test is subjective in that it requires the operator to
visually determine the relative sizes of the particles,
aided by grid markings on the eyepiece of the micro-
scope. Also, the test may take several hours to set up
and carefully run each sample. One major benefit is
that the operator can visually identify some contami-
nants such as metal chips or dirt, and in some cases,
identify the source of the contamination. This may be
of particular value in the quality control of high perfor-
mance fluids.
• Particle Count, Electronic
In this procedure, the fluid sample is placed in the path
of a controlled light beam. The number and size of the
particles in the fluid will determine how much light is
150 200
a photo-detector. The system then calculates the num-
ber of particles in pre-determined size ranges and dis-
V01809 plays the count.
The test is considerably faster than the visual method,
with data available in a few minutes for each sample.
The accuracy will depend on the types of particles
present, as some translucent particles may not be
detected. The count and size will also vary according
to the orientation of the particle in the light beam,
especially for unusually shaped particles such as
those that are long and thin. By and large, however,
the method is relatively accurate and reproducible, and
is frequently used when prompt results are important.
It does not provide any information on types or sources
of contamination.
11
 AU T O M A T I C TR A N S M I S S I O N F L U I D — TE C H N I C I A N ’S G U I D E

MEASUREMENT OF IMPORTANT FLUID

CHARACTERISTICS AND REACTIONS (cont’d)

• Atomic Absorption worn component. It has found particular application

In this procedure, the fluid sample is burned in a high-
temperature flame, and an analytical instrument mea-
sures how much energy was absorbed by a particular
chemical element detector such as iron or tin. The
instrument is specifically calibrated at different ppm
levels for different elements, and as such, provides a
high degree of accuracy for each element examined.
An analysis for ten wear metals would, therefor, require
ten passes through the equipment.
This procedure provides the greatest level of accuracy
per metal analyzed, but it is time consuming. Some
time can be saved by running several dozen fluid sam-
ples for a specific element and then changing the
equipment to the next element. Some labs run so
many samples that they can provide same day service
on a routine basis.
with gas turbines and large, multi-cylinder diesel
engines.
• Chip Detector
Finally, a lesser used technique, ferrous chip detection,
is used when larger particles are suspected present.
This is actually a magnet inserted into the hydraulic
system (usually in place of the drain plug) which has
the ability to attract particles of assorted size. These
particles may then be examined for identification or
weighed for relative comparison purposes.
Figure 8 is a Particle Detection Efficiency Comparison
of the four major detection techniques.
100

• Ferrography Analysis
1 2 3 4
In this procedure, a small sample of fluid is allowed to
EFFICIENCY — %

flow over a glass slide which has been placed in a WEAR

CAUSING
magnetic field. The larger particles tend to collect at PARTICLES
WEAR
the entrance end of the slide, while the smaller parti- METALS
cles collect at the exit end. In general, normal rubbing 50
wear produces enough small particles so that the opti-
cal density at the exit end of the slide is about the
same as that of the entrance end. A rapid increase in
the number of particles (as measured by the optical
density), and in particular, the ratio of large to small
particles, indicates the beginning of a more serious
wear process. Further visual analysis of the metallic 0
5 10 15 40 50 60 100 150 200
wear particles can indicate what type of wear process
is occurring, and with special heat analysis, the type of PARTICLE SIZE (MICRONS)
metal can be identified.
This is perhaps the most sophisticated procedure for 1. EMISSION SPECTROSCOPY/ATOMIC ABSORPTION
2. PARTICLE COUNT
wear metals analysis, and certainly the most 3. FERROGRAPHY
expensive with individual sample analysis costing 4. CHIP DETECTOR
several hundred dollars. The value, however, is in its
V01810
early detection of component wear, in isolating the
type of wear that is occurring, and in identifying the Figure 8. Particle Detection Comparison

12
 AU T O M A T I C TR A N S M I S S I O N F L U I D — TE C H N I C I A N ’S G U I D E
DESIGNING A FLUID ANALYSIS PROGRAM
Designing an effective fluid analysis program and inter-
preting the results is no easy task. Because the highly
technical nature of fluid analysis and the complexity of
automatic transmissions, the serious company should
utilize only an analyst trained in both oxidation and
contamination analysis. A carefully planned analysis
program should include 1) a specific sampling plan
and 2) selected tests including results of and reactions
to those tests.
SAMPLING
Developing a proper sampling technique is the first
step toward meaningful fluid analysis. The importance
of this function is often overlooked, resulting in
reduced program effectiveness. To maximize program
effectivity, the sample should be representative, timely,
and well documented3 as shown in Table 2.
Table 2. Sampling
A fluid analysis program is most effective if fluid
samples are:
• Representative:
– Operating Temperature
– Proper Location
– Clean
• Timely:
– When submitted
– When analyzed
• Documented:
– Transmission unit
– Sampling method
• Representative
A good sample must be representative of the fluid in
service if the analysis result is to be meaningful. First,
the sample should be taken at operating temperature
and while the system is in operation or immediately
thereafter. This will ensure that wear and dirt particles
will not have settled, and that water and coolant have
not yet separated.3 Second, the location from which
the sample is drawn must be carefully selected and the
sample drawn in a manner that ensures cleanliness.
Some systems have a sample valve located on a low-
pressure return line but such a valve is not necessary.
A suction gun inserted into the dipstick tube will also
provide a good sample. In either case, great care
should be taken to avoid contaminating the sample
with any external debris from around the valve or dip-
stick tube. If the sample is being drawn from the dip-
stick tube, the sample tube should be inserted only far
enough to draw the sample. No contact should be
made with the bottom of the reservoir nor should the
sample be drawn any closer to the bottom than neces-
sary. Sludge and dirt collect on the reservoir bottom
and sampling there will result in an inaccurate assess-
ment of the operating fluid. No sample should be taken
from the fluid filter assembly. Third, the sample con-
tainer is just as important as the sample itself. Old
paint or coffee cans may be great for pain thinner, but
they just won’t work for fluid analysis.3 Most laborato-
ries will supply suitable sample containers and a dip-
stick draw system.
All tests are most meaningful when compared to a
like test on a new sample of the used fluid being
evaluated.
• Timely
A fluid sample is drawn and analyzed to provide infor-
mation on the condition of the fluid for the express pur-
pose of protecting the unit and providing early warning.
Therefore, it is important that the sample be submitted
for analysis in a timely manner, preferably the day it is
drawn. Competent labs will analyze the sample and
respond promptly. Excessive delays between sample
draw and sample analysis reduce the significance and
advantage of any analysis program.
• Documented
The final important step to effective sampling is docu-
mentation and identification. Analysis results from a
sample will be of little value if they cannot be related to
the transmission from which the sample was drawn for
necessary action, for comparison to previous results,
and storage for future comparisons. Since compari-
sons will be made, all samples must be drawn in the
same manner, under the same conditions, from the
same location, sent to the same lab, etc. Only then will
comparative results be meaningful.
13
 AU T O M A T I C TR A N S M I S S I O N F L U I D — TE C H N I C I A N ’S G U I D E
DESIGNING A FLUID ANALYSIS PROGRAM (cont’d)
TEST SELECTION AND UTILIZATION
Analysis laboratories offer an almost unlimited variety
of tests through which a customer must sort and select
appropriate tests. Some laboratories may understand-
ably be sales oriented and attempt to sell testing
beyond the economical needs of the customer. The
most useful and economical tests are those that moni-
tor oxidation and viscosity changes, contaminant lev-
els, and wear metal levels of the fluid. While
usefulness will vary according to individual customer
needs, the typical program should place emphasis on
monitoring oxidation and viscosity changes.
Determining the specific fluid change interval suffi-
cient to protect the transmission in any application
remains the responsibility of the customer. Failures
resulting from operating with oxidized fluid likewise
are the responsibility of the customer.
• Monitoring Oxidation State
Fluid oxidation can be monitored by testing for viscos-
ity, and total acid number. Transmission protection and
fluid change intervals can be optimized by monitoring
oxidation according to the tests and limits shown in
Table 3. Notice that most of the limits are a reference
from new fluid; all tests are most meaningful when
compared to a like test on a new sample of the used
fluid being evaluated. A fluid is considered to be suit-
able for use as long as it meets all four limits listed in
the table, regardless of color or odor. However, if one
of the limits is exceeded, the fluid in the subject trans-
mission should be sampled again immediately to verify
the exceeded limit. If verified, the fluid should be
changed regardless of time or mileage. Oxidized fluid
will lead to transmission malfunction and failure. While
fluid change intervals are typically recommended by
component manufacturers, they are, by necessity, only
broad recommendations. As severity of service appli-
cation increases, fluid life decreases through oxidation.
The importance of monitoring fluid condition cannot be
overemphasized.
14
Table 3. Fluid Oxidation Measurement Limits
CONDITION LIMIT
Viscosity +/- 25% Change From New
Fluid
Carbonyl + 30* Change From New Fluid
Absorbance
Total Acid + 3.0** Change From New Fluid
Number (TAN)
Solids 2% By Volume Maximum
* Carbonyl absorbance units/cm
** mg of KOH required to neutralize a g of fluid
Variation in oxidation rates of fluids within a given
component and application is a function of the
fluid, not the component.
• Monitoring Contaminant Levels
The presence of fluid contaminants in an automatic
transmission can be detrimental to continued operation.
Identifying the contaminants and their quantity is most
often useful in post-failure investigation. Its usefulness in
pre-failure investigation is limited by fluid sample deliv-
ery, test, and response time. Depending on the contami-
nant and its level, failure may occur before the
contaminant presence is known. Nonetheless, the infor-
mation can still be useful in changing a policy, activity, or
defect, thus preventing a repeat of the problem. Water
and glycol are probably the most common and harmful
contaminants found in a transmission. Water is a very
poor lubricant and promotes rust, both of which lead to
failure. Perhaps the greatest danger, however, lies in its
effect on clutch plates. Water can penetrate the facing of
a clutch plate and rust the steel core. This rust causes
core and facing separation, leading to clutch pack failure.
Glycol also causes core and facing separation by attack-
ing the bonding material used to join them. The result is
the same — clutch pack failure. Detecting these contam-
inants prior to failure requires rapid testing and
response; value of the tests is most often realized in fail-
ure identification. Prior to failure, if water or glycol is
detected, the fluid should be changed and the source of
the contaminant identified and corrected.
 AU T O M A T I C TR A N S M I S S I O N F L U I D — TE C H N I C I A N ’S G U I D E

DESIGNING A FLUID ANALYSIS PROGRAM (cont’d)

Abrasive debris such as road sand or dirt can Table 4. Contaminant Limits
accelerate wear of the transmission and can be
monitored prior to failure. Debris testing is not as CONTAMINANT LIMIT
important as other tests since a maintained filtering
system will usually remove the bulk of the damaging Water 0.2% Maximum
abrasive particles.
Glycol 0; No Trace Allowed
In some applications, engine oil can leak past the rear Road Debris No Limit Established (Maintain
engine seal and eventually overfill the transmission. Filtering System)
Since most engine oils are compatible with
transmission fluids, the engine oil itself is not harmful, Engine Oil No Limit, Provided
but an overfill condition is. Through aeration, overfill Transmission Level is
can lead to reduced clutch pressure, erratic shifting Maintained
and subsequent clutch failure. If engine oil
Alien Fluids No Limit Established. If
contamination is suspected, emission spectroscopy
Detected, Change
analysis of a sample of new engine oil should be
Transmission Fluid
compared to a sample of new transmission fluid. An
element unique to the engine oil should be evident.
• Monitoring Wear
Subsequently, presence of that unique element can be
monitored in used transmission fluid samples. If the During normal operation, different components within
element unique to the engine oil is present in the used
the transmission will experience wear. As a result of
transmission fluid, then engine oil contamination is
this wear, microscopic particles will enter the fluid
confirmed. In addition, two ASTM tests will detect the
which are small enough to pass through the external
presence of soot, a by-product of engine combustion.
and sump filters. Fluid laboratories are equipped
Those tests are the Cleveland Open Cup (though it
(emission and atomic absorption spectroscopy) to
has been questioned) and the Pentane Insolubles. If
determine the elemental composition of the micro-
engine oil is detected, transmission fluid level must be
scopic particles and will report their test results in ppm.
carefully monitored and maintained. Once the engine
Transmission fluid wear metal analysis is concerned
leak has been corrected, the transmission fluid should
with monitoring the identity and the levels of these
be changed.
wear materials in the fluid. Recording the concentra-
Finally, a completely alien fluid, i.e., brake fluid, tion levels of these particles over a period of time pro-
inadvertently introduced into the transmission, can be vides information on the wear rate of certain internal
detected by a radical change in value on an IR scan at components. Table 5 is a list of elements typically iden-
wavelengths of 3.5 and 5.8 microns. If an alien fluid is tified by a spectrographic analysis of transmission fluid
suspected, the transmission fluid should be changed. and includes possible sources. This information can
Table 4 on Contaminant Limits provides a listing of only be meaningful, however, through a prescribed
typical contaminants and comments on limits. procedure.

15
 AU T O M A T I C TR A N S M I S S I O N F L U I D — TE C H N I C I A N ’S G U I D E

DESIGNING A FLUID ANALYSIS PROGRAM (cont’d)

Table 5. Sources of Wear Metals and ATF Analysis Elements

ELEMENT ELEMENT SOURCE

Aluminum On-Highway: main case, converter, pistons.
Off-Highway: converter, some valve bodies.
Barium Detergent additives.
Boron Detergent additive, supplementary coolant inhibitor additive.
Calcium Detergent additive, sometimes present in road salt and “hard” water.
Copper Bushings, thrust washers, bearings, cooler tube bundles.
For off-highway only, sintered bronze clutch plates.
Iron Wide range of parts throughout transmission. Common source: any rotating part.
Lead Babbitt found in some bushings.
Magnesium Detergent additive, traces in aluminum alloys, frequently present in hard water.
Molybdenum Friction modifier additive.
Phosphorous Wear inhibitor additive.
Silicon Silicone gasket material, silicone anti-foam additive, ingested airborne sand or dust,
alloying element in aluminum.
Silver Specialized applications: sealrings, bearings, hydrostatic components.
Sodium Detergent additive, supplementary coolant inhibitor additive, road salt.
Tin Babbitt found in some bushings, bronze bushings, thrust washers or some clutch plates.
Zinc Wear and oxidation inhibitor additive, brass components: speedometer gears, fluid
couplings, etc.

Absolute maximum values cannot be applied to wear
metals of an automatic transmission due to the many
variables present that affect concentration limits.
Extended studies have indicated that significant varia-
tion exists between units, models, applications, labora-
tories, interpretations, etc., rendering universal limits
nearly impossible, even within a given model series.
Wear metal analysis results must be evaluated using a
“trendline” approach. Specifically, the concentration
level of each wear metal from each transmission must
be plotted over a period of time. A line of best fit drawn
through the plotted prints is considered the “trendline.”
Four data points are generally sufficient to establish a
trend. The first data point should be from a sample of
new fluid establishing initial levels. The trendline is
then projected beyond the plotted points and becomes
the baseline by which future concentration levels will
be judged. Subsequently, cause for concern should
only be significant deviations from the projected line.
A sample trendline plot is shown in Figure 9.
While trendline analysis on wear metals can prove infor-
mative and useful, a transmission removal decision
should not be based solely upon the analysis. The
results should be used in conjunction with other inspec-
tion procedures such as a functional check, road test or
a pan inspection. A removal based solely on wear metal
analysis may result in an unnecessary teardown. Wear
metal analysis should be considered an early warning
signal indicating a need for further investigation, not
immediate removal. The removal should occur only if
the additional investigation warrants it.

16
 AU T O M A T I C TR A N S M I S S I O N F L U I D — TE C H N I C I A N ’S G U I D E

DESIGNING A FLUID ANALYSIS PROGRAM (cont’d)

user should evaluate individual needs and determine

A removal based solely on wear metal analysis
may result in an unnecessary teardown.
In summary, emphasis again is placed on monitoring
fluid oxidation. However, the monitoring of contami-
nants and wear metals may well prove useful depend-
ing on the particular circumstances of the user. The
the economics of each test being considered. In any
test selected, the user should remember the impor-
tance of proper sampling and the need for analysis of a
sample of new fluid to establish a baseline for evalua-
tion of subsequent analysis of used samples. Use of
these techniques and a competent laboratory will
insure maximum fluid analysis program efficiency.

WEAR ELEMENT: COPPER

(SAMPLE GRAPH ILLUSTRATING DEVIATION
BEYOND PROJECTION)

ACTUAL SAMPLE VALUES

PROJECTED SAMPLE VALUES

100% + ABOVE
PARTS PER MILLION

50 – 99% ABOVE PROJECTION

0 – 49%

3,000 6,000 9,000 12,000 15,000 18,000 21,000

MILES

5,000 10,000 15,000 20,000 25,000 30,000 35,000

KILOMETERS V01811

Figure 9. Sample Trendline Plot

17
 AU T O M A T I C TR A N S M I S S I O N F L U I D — TE C H N I C I A N ’S G U I D E
FLUID SELECTION
Proper function and durability of an automatic
transmission can be noticeably influenced by the
fluid with which it is serviced.
RECOMMENDED FLUIDS
TranSynd™ — TranSynd™ is a full synthetic auto-
matic transmission fluid5 from Allison Transmission
Division and Castrol Ltd. TranSynd™ meets new Alli-
son specifications for Severe Duty and Extended
Drain Intervals (TES-295). TranSynd™ is available
through Allison distributors and dealerships. Tran-
Synd™ is also fully qualified to the Allison C-4 specifi-
cation and the GM DEXRON®-III specification.
DEXRON®-III Automatic Transmission Fluids —
DEXRON® is a registered trademark of the General
Motors Corporation. Proper use of this trademark
requires that the GM license number be included on
the product container. The GM license number is a five
digit number preceded by the letter designation “G”
(example: GXXXXX). DEXRON®-III transmission fluids
are dyed red in color for identification purposes. Some
DEXRON®-III automatic transmission fluids qualify to
the Allison C-4 specification.
C-4 Fluids — Some approved C-4 products are heavy
duty diesel engine oils. A variety of SAE viscosity
grades (i.e., SAE 30, 15W-40, etc.) have been
approved to the C-4 specification. Also, some
DEXRON®-III automatic transmission fluids qualify as
a C-4 fluid. These oils are tested and evaluated in
accordance with the Allison C-4 Transmission Fluid
Specification (TES-228). An approved oil list
18
(GN3465EN) is available from your local Allison
dealer/distributor or via the Allison website at
www.allisontransmission.com.
OTHER FLUIDS AND ADDITIVES
A wide assortment of fluid manufacturers offer an
almost unlimited variety of fluids and additives to
consumers today. Some of these manufacturers publish
sales material that makes very impressive claims about
their products. It is often supported by selected field
data. While these claims may well be valid, ATD cannot
take the responsibility of evaluating data or validating
the claims of any manufacturer. GM and ATD have
designed specific tests that thoroughly evaluate the
ability of the fluid to perform well and protect their
products. Consequently, ATD can only approve a fluid
that has passed the appropriate tests and been granted
a DEXRON®-III license or C-4 approval number. No
other fluid or additive can be approved, regardless of
the claims of the manufacturer or the validity of the
supportive data; the marketer must initiate participation
in the appropriate tests. This requirement is designed to
protect the user as well as the transmission
manufacturer because optimal transmission life will be
realized only when it is serviced with a quality fluid. An
approved fluid has all the additives it needs and addition
of others, besides being unnecessary and expensive,
may upset the chemical balance and effectivity of the
original additives.
Selection of an approved fluid and its singular use
will ensure customer satisfaction.
 AU T O M A T I C TR A N S M I S S I O N F L U I D — TE C H N I C I A N ’S G U I D E
FLUID STORAGE AND HANDLING PRECAUTIONS
Because lubricating fluids are generally based on
petroleum or related hydrocarbons, they have certain
inherent characteristics of which the user should be
aware. There are, of course, no unusual hazards asso-
ciated with most lubricating fluids provided reasonable
care is taken with their storage, handling and usage.6
Cleanliness and orderliness cannot be overempha-
sized.
STORING AND HANDLING
Where possible, a specific room or at least a
designated area should be reserved for fluid storage
rather than randomly placed containers. A specific
storage area will lend itself more readily to order and
cleanliness. Order must be maintained to ensure that
inadvertent mixing of non-similar fluids — engine,
transmission, power steering, brake — does not occur.
The storage facility should be heated and the
temperature stabilized to avoid moisture condensation
and separation of additives. Drums should be stored
on their sides to prevent water contamination;
improper storage of drums is the primary cause of
water contamination. When drums are stored on end,
temperature fluctuations can draw water along the cap
threads and into the drum. Cleanliness is also an
essential part of proper storage. It is important in
preventing contamination of the fluid as well as
contamination by the fluid. Not only must the fluid be
kept clean, but the floor must be kept free of fluid for
obvious safety reasons. The cleanliness standard must
also be extended to the transfer containers, pumps,
measuring cans, etc. These containers should be
cleaned with mineral spirits since it evaporates entirely
and will keep the equipment clean without the danger
of product contamination.6
HEALTH ISSUES6
There are no unusual hazards in using most
lubricating fluids provided ordinary and reasonable
care is taken to keep them off the skin, away from the
eyes and to avoid breathing their vapors or mists.
Inhalation of fluid mist is always to be avoided. If
inhaled in high enough concentrations, fluid mist can
cause irritation of the lungs which may lead to
pneumonia. Medical problems arising from contact
with petroleum-based fluids are relatively infrequent
and occur chiefly in circumstances where there is
excessive bodily contact; i.e., where fluid soaked
clothing is not regularly changed.
The principle problem associated with the handling of
lubricant fluids is dermatitis resulting from prolonged or
repeated contact with the skin. This is characterized by
acne-type lesions mainly on the back of the hands and
on the forearms and thighs where the hair follicles and
sweat pores can become infected with the formation of
small boils or pimples. In general, dermatitis is not a
problem if unnecessary contact with the fluid is
avoided and good personal hygiene and cleanliness
are always observed.6 The remote risk is further
minimized by the use of a barrier and reconditioning
skin cream.
Consult your transmission fluid supplier with any
questions about storage, handling, and/or health
issues. The supplier can furnish a copy of the
appropriate Materials Safety Data Sheet (MSDS) for
the product in use.
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SUMMARY

As emphasized throughout this booklet, effective fluid
analysis is only possible though the use of a trained
analyst who is familiar with fluids, fluid analysis, and
the subject hydraulic components. The competency of
the analysis laboratory understandably plays an impor-
tant part as well.
The competent lab will provide quality and timely
analysis, sell only those tests that are needed, and
stick to reporting the facts of fluid condition and
contaminant levels, leaving judgments on compo-
nent condition to the component manufacturer.
entire organization must be committed to the fluid
analysis to realize any benefits.
If there is ever any doubt on the significance of any
fluid analysis reports, or a need to react to a condi-
tion, the user must remember that the vehicle or
component manufacturer is the final authority on
the product and assistance should be sought
through a servicing outlet or a regional office.
Table 6. Summary

The prime intent of fluid analysis should be to THE SERIOUS FLUID ANALYSIS USER WILL:
monitor the functional capability of fluid — can it
• Utilize a Trained Expert
do its intended function?
• Utilize a Competent Lab
Primary hindrances to fluid capability are oxidation and
contamination, and fluid analysis program funds are • Utilize Only Justifiable Tests
best spent in those areas. Wear metal analysis can
also prove useful but should be analyzed by the • Utilize Proper Sampling Techniques
“trendline” method. Wear metal analysis seldom
• Recognize the Manufacturer as the Expert
stands alone; it must be used in conjunction with other
inspection techniques. • Utilize Manufacturer Recommendation
The assigned analyst should study the analysis tech-
niques and recommendations in this booklet along with • Assure Commitment to the Program
other available information, establish a meaningful pro-
gram, and then supervise it with commitment. The • Utilize Common Sense

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COMMON MISCONCEPTIONS

Table 7. Common Misconceptions

MISCONCEPTION REALITY

Fluid never wears out. Even in an isolated, clean system, fluid will oxidize with time; it has
a finite life.

Fluid brands should not be mixed. Fluid brands may be mixed as long as they are approved fluids.

DEXRON®-III and C-4 should not be mixed. DEXRON®-III and C-4 may be mixed, though this should not be
standard practice.

Overfill is better than underfill. Overfill, through heat and aeration, is just as harmful as underfill.
Care should be exercised to maintain proper fluid level.

Color or odor can indicate fluid change need. Color and odor are not indicative of fluid change need. Fluid
change interval should be established as described in the Fluid
Analysis Utilization section.

Use extra additives at fluid change. An approved fluid has all the additives it needs. Addition of more is
expensive and could be harmful.

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DEFINITION OF
TERMS AND ABBREVIATIONS
Acid Number — Property of petroleum fluid usually
measured by the amount of potassium hydroxide
(KOH) needed to neutralize all or part of the fluid’s
acidity.
Additive — Anything added to a petroleum or syn-
thetic base fluid to alter its natural properties or perfor-
mance characteristics.
Anti-Foam Agent — A petroleum additive that
reduces surface tension thereby assisting a fluid in the
release of air bubbles.
Anti-Oxidant — A petroleum additive that works on a
molecular scale, sacrificing itself to the oxidation pro-
cess thus limiting oxidation of the lubricant.
Anti-Wear Agent — A petroleum additive that protects
metal surfaces by chemically reacting with or plating
onto a surface and wearing in place of the surface.
API — American Petroleum Institute.
Aromatic — One of the three types of petroleum fluid.
Derived from aromatic crude oil, thus containing a high
proportion of closed-ring Benzene groups.
ASTM — American Society for Testing and Materials
(Philadelphia, PA).
ATF — Automatic Transmission Fluid
Base Fluid — Refers to a synthetic or petroleum fluid
prior to the inclusion of additives. The three basic types
are naphthenic, paraffinic, and aromatic.
Base Number — Property of petroleum fluid usually
measured by the amount of acid (expressed in potas-
sium hydroxide (KOH) equivalents) that the fluid can
neutralize.
C-4 — A fluid quality specification designed and main-
tained by ATD primarily intended for off-highway trans-
mission use. Also approved for on-highway use.
Carbonyl Absorbance — An indication of oxidation
found by measuring the amount of infrared light
absorbed at a 5.8 microns IR wavelength.
Centipoise (cP) — One-hundredth of a poise which is
the dynamic measurement unit of the resistance of a
fluid to flow defined by the shear stress required to
move one layer of fluid along another over a total layer
thickness of one centimeter at a shear rate of one cen-
timeter per second. Independent of fluid density and
directly related to resistance to flow.
22
Centistoke (cSt) — One-hundredth of a stoke which is
the kinematic measurement unit of the resistance to
flow of a fluid defined by the ratio of the viscosity of a
fluid to its density.
Cloud Point — The temperature at which a cloudy
haze initially appears when the fluid is cooled under
prescribed controlled conditions. It is indicative of the
temperature at which a gel, partially consisting of wax
crystals, begins to form.
ATD — Allison Transmission Division of General
Motors.
Demulsibilty — A measure of the ability of a fluid to
separate from water.
Detergent — A petroleum additive that cleans or
maintains cleanliness of the working parts of the
equipment wetted by the host fluid. Sometimes used
interchangeably with dispersant though they are tech-
nically different.
DEXRON®-III — A registered trademark of General
Motors used to designate fluids designed exclusively
for on-highway products. Often mistakenly pronounced
DEXTRON.
Dispersant — A petroleum additive that disperses or
maintains in solution normally insoluble products of
combustion and contaminants.
Elemental Analysis — The activity of detecting and
identifying elements in solution or microscopic suspen-
sion in a fluid sample. Typically used to measure wear
metals.
Emulsify — The ability of a fluid to suspend and dis-
perse an immiscible (incapable of mixing) liquid such
as water.
EP Agent — Extreme Pressure agent — a petroleum
additive that chemically reacts on highly-stressed and
loaded metal surfaces forming a protective chemical
barrier (dry lubricant) capable of withstanding greater
loads.
Esterification — The process of creating an ester; the
resultant of a chemical reaction of organic acids and
alcohol; one method of creating a synthetic fluid.
Flashpoint — The minimum temperature at which a
fluid will just support instantaneous combustion (a
flash) but before it will burn continuously (fire point).
Fluid — Typically used to refer to petroleum or synthetic
lubricants for application other than engines (oils).
 AU T O M A T I C TR A N S M I S S I O N F L U I D — TE C H N I C I A N ’S G U I D E
DEFINITION OF
TERMS AND ABBREVIATIONS (cont’d)
Friction Modifier — The petroleum additive that
reduces the coefficient of friction of a fluid making the
fluid more lubricious.
Hydrocarbon — A compound consisting mainly of
hydrogen and carbon; commonly petroleum.
Hydrofinishing — A process for treating raw extracted
base stocks with hydrogen to saturate them for
improved stability.
Hydrolysis — The decomposition of a chemical com-
pound, such as a fluid additive, when exposed to
water.
Inhibitor — Any additive used to inhibit or control an
undesirable reaction or process which could reduce or
destroy the usefulness of a fluid; i.e., oxidation inhibi-
tor, rust inhibitor, etc.
Insolubles — Contaminants found in used fluids due
to dust, dirt, wear and/or oxidation. Often measured as
having a pentane- or benzene-insoluble character.
IP — Institute of Petroleum (London, England).
IR Scan — Infrared scan; the process of exposing a
fluid sample to infrared light at various wave-lengths
and measuring the amount of light absorbed.
KOH — Potassium Hydroxide
Karl Fischer Reagent — A colored solution of pyri-
dine, sulfur dioxide, iodine, and anhydrous methanol
that reacts quantitatively with water to form a colorless
solution and is used to determine the amount of water
in numerous substances.
Lubricant — A fluid whose prime intended function is
the reduction of friction through lubrication.
Lubricious — Term used to indicate a smooth or slip-
pery quality.
Lubricity — The property or state of being lubricious:
the capacity for reducing friction.
Multi-Vis — Short for multi-viscous. Refers to a fluid
having multiple viscosity characteristics according to
temperature; i.e., 10W30. The multi-viscous character-
istic is obtained through the use of an additive, a Vis-
cosity Index (VI) Improver.
Naphthenic — One of three types of petroleum fluid.
Derived from naphthenic crude oil, thus containing a
high proportion of close-ring methylene groups.
Neutral Oil — Lubricant stocks that are light overhead
cuts from vacuum distillation measured in SUS at
100˚F (38˚C). These oils are the basis of most com-
monly used automotive and diesel lubricants.
Oxidation — The process of oxygen attacking petro-
leum fluids. Accelerates at high temperatures and with
increased exposure to air. Usually leads to viscosity
increase and deposit formation.
Paraffinic — One of three types of petroleum fluid.
Derived from paraffinic crude oil, thus containing a
high portion of straight-chain saturated hydrocarbons.
Often susceptible to cold flow problems.
Polymer — A complex chemical compound of high
molecular weight obtained from the combination of
lower weight molecules. Best visualized as a long
chain of molecules.
Polymerization — The process of creating a polymer,
one method of creating a synthetic fluid.
Pour Point — Usually the lowest temperature at which
a substance will flow. Lack of fluidity of a naphthenic
fluid stems from the increase in viscosity while that of a
paraffinic fluid is due to the formation of wax crystals.
The pour point can be lowered by additives.
SAE — Society of Automotive Engineers.
Saybolt Universal Seconds (SUS) — A unit used to
measure the relative viscosity of fluids under controlled
laboratory conditions of temperature and volumes; the
static measurement of viscosity.
Shear Index — The measure of the percentage of vis-
cosity loss in a fluid.
Shearing (Polymer) — Shearing of a polymer is liter-
ally a splitting, cutting, or dividing of the molecule into
two parts having lesser molecular weight. The end
result of shearing is a reduction in fluid viscosity.
Shear Stability Index — The measure of the contribu-
tion of the VI Improver to the percentage of viscosity
loss of the fluid.
Sludge — An undesirable, insoluble substance that
forms due to fluid oxidation and/or interaction with
water. Sludge can drop out of the fluid, depositing onto
internal components causing malfunction.
Straight Grade — Refers to a fluid exhibiting only one
viscosity characteristic; i.e., 10 weight has no VI
Improvers.
Tribology — The science of lubrication, friction, and
wear.
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 AU T O M A T I C TR A N S M I S S I O N F L U I D — TE C H N I C I A N ’S G U I D E
DEFINITION OF
TERMS AND ABBREVIATIONS (cont’d)
User — Refers to the final purchaser and user of a
product.
Varnish — A non-wipeable deposit which can be
found on the working parts (especially friction-faced
clutch plates) of a transmission. Excessive varnish can
interfere with proper function. Also referred to as lac-
quer.
Viscosity — A measure of the resistance of a fluid to
flow due to internal molecular friction; the thickness of
a fluid. Centipoise, centistoke, and Saybolt Universal
Seconds are common measurement terms.
24
Viscosity Index (VI) Improver — Oil-soluble polymer
chains with very high molecular weights. A fluid addi-
tive designed to reduce the thinning effect of increas-
ing temperature. Polymer chains swell with
temperature thus imparting a thickening effect as tem-
perature increases.
Wear Metals — Refers to microscopic metal particles
or metal in solution in the fluid. Can be indicative of
component wear.
 AU T O M A T I C TR A N S M I S S I O N F L U I D — TE C H N I C I A N ’S G U I D E

FOOTNOTES

This booklet was written and compiled from the following sources:
1. H. E. Deem and J. Ryer, “Automatic Transmission Fluids — Properties and Performance,” The Exxon
Chemical Co., a Society of Automotive Engineers Publication 841214.

2. “What You Should Know About Lubrication,” a Technical Publication by the Texaco Co.

3. “Oil Analysis,” Fluid Marketing Corporation, Reprinted Article from Fluid & Lubricant Ideas Magazine.

4. A. N. Roush, “Quality Transmission Lubricants,” Equipment Management, July, 1984, D-A Lubricants Co.,
Inc., Indianapolis, Indiana.

5. T.L. Johnson, Introducing TranSynd™, A New Severe Duty Extended Drain Interval Fluid for Allison Heavy
Duty Automatic Transmissions, SAE Publication 982798, 1998.
6. P. J. Fraser, “The Safe Handling and Use of Lubricating Oils and Greases,” The Canadian Lubrication
Journal, Vol. 1, #2, 1981.

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NOTES

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NOTES

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GN2055EN 200103 www.allisontransmission.com Printed in U.S.A. 200105