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The rheological behavior of automatic transmission fluids (ATF) ranges from moderately shear-thinning to Newtonian. However, no commercially available ATFs are known to display shear-thickening behavior. A theoretical investigation was performed to determine if any advantages could be derived from the use of shear-thickening ATF in automatic transmission components and subsystems. A series of theoretical shear-thickening, shear-thinning, and Newtonian fluids were modeled by a power law function and compared to a reference shear-thinning ATF in simplified representations of transmission components and subsystem geometries. The results indicate that a shear-thickening ATF with zero shear viscosity, infinite shear viscosity, and power of 417 mPa-s, 6.23 mPa-s, and 1.03(dimensionless), respectively, displays optimized behavior with respect to the reference shear-thinning ATF.

Using standard industry tests, the oxidation stability of General Motors current factory-fill automatic transmission fluid (ATF) was compared to that of a proposed factory-fill ATF to be introduced for the 1995 Model Year. Full-scale transmission tests and Aluminum Beaker Oxidation Tests run at various temperatures showed that a proposed factory-fill fluid is substantially more resistant to oxidation than the current factory-fill ATF. Using Total Acid Number increase (Δ-TAN) as the measure of oxidation, a minimum of 35% improvement was obtained with a proposed factory fill. This improvement at least doubles the time to “perceived fluid failure” (Δ-TAN = 2.5).

An integrated approach to modeling end of useful life of an automatic transmission fluid (ATF) has been developed. The flexible fluid life model allows either predictive or real-time calculations of the end of useful fluid life under different transmission design strategies and customer driver behaviors as reflected in operating temperatures, shift characteristics, fluid volume and fluid distribution throughout the transmission. An estimation of remaining useful fluid life is monitored using two metrics, namely bulk oxidation, as a general indicator of fluid quality, and frictional degradation, as an indicator of shift quality. As operating conditions increase in severity, ATF is subjected to conditions that may shorten its life. Using the developed technique, ATF useful life can be better predicted.

General Motors (GM) currently uses about 1000 different seals for manufacturing all of its automatic transmissions worldwide. In order to assure that these seals function correctly in service, a method of measuring seal performance with service fill automatic transmission fluids (ATFs) has to be specified. Along with this measure, a pass/fail criterion for the evaluation of seal performance is implemented. Due to the large number of seals that are utilized, it would be impractical to test each one with every fluid that is submitted for GM DEXRON®-III and/or Allison C4 certification. It is also very difficult to use production seals in testing, due to the irregular shapes and material combinations, which make measurement of the seal material properties difficult. Therefore, a revised test will be included in the DEXRON®-III and Allison C4 service fill specifications to evaluate the compatibility of service fill ATFs with a representative sample of seal materials used in production.