Technical Report No. 11540

INSTALL AND EVALUATE 3 SPEEDAUTOMATIC TRANSMISSION ANDFULL TIME ALL WHEEL DRIVE

SYSTEM IN AN M151A2

Final Engineering Report

June 1972

Prepared by:

C. E. Johnson, Jr.H. D. Hahn

PERFORMED UNDER THE TECHNICAL SUPERVISION OFPROPULSION SYSTEMS LABORATORY

U. S. ARMY TANK-AUTOMOTIVE COMMAND

Contract DAAE07-70-C-4632

Warner Gear DivisionBorg-Warner Corporation1106 East Seymour StreetMuncie, Indiana 47302

Reproduced FromI'll Ilk iBest Available Copy

ABSTRACT

This report concerns the modification and evaluation of

an M151A2 with the installation of a three speed automatic

transmission and a full time all wheel drive system. The

automaticity of this total system reduces driver training,

increases mobility and improves handling characteristics

and drive line life.

Design layouts and detail drawings suitable for

fabrication of hardware were completed under the contract.

A detailed description of the system operation and perfor-

mance capabilities is included in this report.

This system is recommended for wheeled vehicle applications

using gasoline, diesel and turbine engines.

ii

TABLE OF CONTENTS

Page

Abstract .... .. .. .. .... .. .. .. .. .. .. . ..

I. Introduction ..................... 1

II. Summary.................. . . ... 3

III. Description of Work .............. .... 4

IV. Delivered Components. ................. 10

V. Performance....... ... . .. .. .. .. . . . . . 11

VI. Automatic Transmission Calibration. ........ ... 12

VII. Transfer Case Calibration . . . . .. .. .. .. .. 13

Michael's Letter August 20, 1971

a. Appendixb. Performance Summaryc. Performance Curves A-1 thru A-8 and B-1 thru

B-2d. Vehicle Sheet Metal Sketch

I. INTRODUCTION

This report summarizes the work accomplished under Con-

tract DAAE07-70-C-4632. This contract required Warner Gear

Division to provide supplies and services for the installation

and evaluation of a three speed automatic transmission and

full time all wheel drive system in an M151A2 vehicle. The

scope of work is as follows:

"The Contractor shall provide services, supplies

and facilities to accomplish the following work:

a. Install one automatic three speed trans-mission (Borg-Warner Model 40) with anattached two speed transfer transmissionand differential in a Government-furnishedTruck, 1/4 Ton, 4x4, M151A2.

b. The transfer unit shall be a chain driveand shall have two ratios, a hi and lorange. The ratios shall -be capable ofbeing changed while the vehicle is standingor in motion. Current "high center" roadclearance of the M151 vehicle shall bemaintained. Provide an interaxle limitedslip differential. Provisions for aparking brake are required.

c. Make all necessary vehicle modificationsto accomplish the installation includingengine, propeller shafts, controls, linkages,cooling, etc.

d. Provide and install transmission coolersof sufficient capacity to cool the trans-mission while the vehicle is operating atrated load on a 60% slope.

e. The transmission and drop box must operateat a 60% fore and aft slope and a 40% sideslope.

f. Operate the vehicle for 500 miles to assureproper functioning of the installation.

g. Provide sketches and data of vehicle modi-fications required to accomplish installation."

2

II. SUMMARY

A. OBJECTIVE

1. To install and evaluate an automatic drive line

system in an M151A2 vehicle.

2. To provide drawings, sketches and other data to

describe and support the objective.

B. CONCLUSIONS

This system if incorporated would result in performance

and cost advantages in current and future wheeled vehicles.

Some of these advantages are:

...Less driver training

... Increased mobility

...Less drive line component maintenance

...Longer drive line life

...Longer engine life - eliminates "lugging" and

accidental overspeed

...Adaptable to gasoline, diesel or turbine engines.

III. DESCRIPTION OF WORK

The following modifications of the vehicle were necessary

to allow installation of the transmission, transfer case and

reduction assembly.

1. A solenoid was inserted into the starting circuit

so that the "neutral start" switch on the shift

linkage would be effective.

(White Motor Co. 24V relay, no part number available)

2. An oil to air transmission oil cooler was installed

directly in front of the radiator. Steel tubing was

used to route the oil to and from the cooler.

Micro Test Transmission Cooler, National Automotive

Parts Association (NAPA) #1-4752.

3. The rear motor mount was relocated 7.4" rearward of

the existing mount. Their mount consisted of a sheet

metal box welded to the frame with two risers welded

to this box to support the rubber mounts. This box

was left intact since it appeared to contribute to the

structural strength of the unit body. The risers were

removed to provide clearance to the transmission. The

new motor mount was made of a 2-1/2" structural steel

channel and was bolted to the center rails. Risers

identical to the removed pieces were welded to the

steel channel.

4

4. The floor pan was removed between the center rails from

the existing transmission access opening to the back of

the front seats to provide clearance for our unit and

to allow the reduction assembly to be removed for

service without removing the rear motor mount. See

enclosed sketch.

5. A floor mounted shift lever was used. This was mounted

directly above the transfer case in a sheet metal console

which was bolted to the floor pan. Shift pattern was

RND21. The shift lever assembly was modified to prevent

lever travel to "Park" position. The shift arm was

lengthened per sketch #1. The shift lever and arm

assembly was an American Motors Corporation assembly

for their floor shift automatic transmissions. No part

number is obtainable.

6. An opening and cover plate was put into their transmission

access panel to provide access to the automatic trans-

mission fill tube. A sealed fill tube cap and dipstick

was used. Moeller Manufacturing Company #T-2001 modified

by adding dipstick.

7. The manual clutch linkage and pedal was removed.

8. The muffler was relocated to the left side of the vehicle.

9. The front and rear driveshafts were altered in length.

5

10. Handles for two pull cables were mounted in the dash-

board. These control shifting of the reduction unit

and lockup of the interaxle differential in the transfer

case.

11. Since kickdown shifts of our automatic transmission

are controlled by an accelerator operated 12V solenoid

valve an electrical switch was installed on the carbur-

etor. This switch was normally open. The contacts

were closed when the accelerator position was at full

throttle. A 25 watt variable resistor was connected in

in series with the kickdown solenoid to drop the

voltage at the solenoid to 12V. The switch was an

American Motors Corporation kickdown switch (no part

number available).

6

Transmission Buildup

The transmission was built per parts list #SK4493JT except as

noted below:

Name Omit Add Reason

Oil Pan 8G-A180 10-03-513-001 Deeper oil pan usedAssembly for increased oil

capacity for im-proved reliability.

Front Servo ll-lAI20A 5AB-125 Smaller apply areaAssembly 24# spring needed to obtain

5H-119 sleeve acceptable 1-2 shift5H-121 piston quality. Self-11-120A body adjuster is used.

Rear Adapter 11-2A160 12-lAI60A To provide access toand Bushing governor pressure toAssembly activate TCS switch

for smog control.

Governor 5G-A95B 5G-2A95B To give desiredshift points.

Valve Body 10-03-736-014 10-03-736-024 To give desiredAssembly shift points. This

valve body was modi-fied as shown below.

Convertor Listed part was used,Housing but it was necessary

to machine radialclearance for ringgear.

Manual Control 10-03-598-001 No Number Manual control leverLever Assembly changed to provide

clearance with frameManual Control No Number of vehicle.Lever

7

Valve Body Modifications

Primary Regulator Springs #11-250 omitted, #11-243A changed to #11-243

Governor Modulator Spring #10-03-156-011 changed to #8H-215

Servo Regulator Spring #5J-223 added

1-2 shift valve spring #10-03-156-009 changed to 1.7# @ .906"

(no number)

Throttle Modulator Spring #12-216 changed to #11-216; 7.04# @ .710"

2-3 shift valve plug #10-03-237-006 changed to .444 dia. (no number

Orifice in line 9G moved to primary regulator valve end of line

Transfer and Reduction Unit Buildup

The transfer and reduction assembly was built per parts list

#SK4651. The control of the interaxle differential lockup was

by cable without a "preselect" feature.

Name Omit Add

Transfer SK4651-7 Didn't change parts.Case-Rear Added hole in case in SRD

lockup area to allow oilto enter lockup area.

Thrust Washer None 15-21-109-02 Added 2 thrust washersBelleville to to each side of SRDCone-SRD because one spring was

removed from each side(see below).

Belleville 15-21-108-01 None Removed 1 spring eachSpring-SRD side of SRD to reduce

slip torque of SRD

SRD Housing 8424-009-1 Didn't change parts.Added axial groove thrueach cone seat to allowoil flow thru seat.

SRD Pinion 18-01-042-002 Didn't change parts.Shaft Extended ground flats on

pin to end of pin (.070"

deep) to allow oil toescape SRD.

8

Oil

Transmission was filled with Shell 1OW Rotella oil which meets MIL.

SPEC #2104B or C. Fill level is shown on dipstick in fill tube.

Transfer and reduction unit was filled with a mixture of 91%

Valvoline SAE 30W nondetergent motor oil and 9% Lubrizol #762

by volume.

Fill level is to level check plug in transfer unit when filling

slowly thru level check plug in reduction unit.

Weights

As received:

Total vehicle with full gas tank, 2380# totalside curtains, spare tire 1320# front axle

1060# rear axle

Removed components:

Transmission including transfer case 118.#Flywheel 18.Bell Housing 21.Clutch disk and pressure plate 10.Clutch linkage 11.

Total Transmission Components Removed 178.#

As returned with our transmission and transfer case:

Total vehicle 2580# total1440# front axle1140# rear axle

9

IV. DELIVERED COMPONENTS

Automatic Transmission and Extension Housing (drg) 143.#

Convertor Housing 29.

Convertor 18.

Flex Plate and Pilot 5.5

Oil 24.

Transfer and Reduction Assembly 107.

Transmission Oil Cooler and Lines ?

Shift Linkage and Console ?

Rear Motor Mount ?

Starter Solenoid ?

Total Transmission Components 326.5# +

10

V. PERFORMANCE

As received speed measured by vehicle speedometer on

Westinghouse Road. Top up without side curtains.

Load Acceleration Time Top Speed0-50 mph 0-55 mph At End of 1 Mile

2 man 27.2 sec 40.0 sec 58. mph22.1 29.0 58.26.5 38.2 66.20.3 26.7 66.524.5 35.619.5 25.026.5 38.521.0 27.0

23.5 avg 32.5 avg 62 avg

2 man 33.2 47.8 -+ 1000 27.2 39.5# load 33.6 48.2

27.6 34.633.6 47.627.4 34.5

30.4 avg 41.2 avg

Mr. T. L. Michaels of Borg-Warner Research Center conducted

a computerized performance analysis. A copy of his report is

included.

1i

VI. AUTOMATIC TRANSMISSION CALIBRATION

Buildup set at 62 psi at 1000 rpm and 11.0" vacuum

1-2 light throttle shift @ 6 mph

2-3 light throttle shift @ 17 mph

1-2 full throttle shift @ 25 mph @ 3300 ERPM

2-3 full throttle shift @ 40 mph @ 3350 ERPM

1-2 detent shift @ 31 mph @ 3900 ERPM

2-3 detent shift @ 47 mph @ 3750 ERPM

3-2 kickdown maximum 42 mph

3-2 part throttle maximum 28 mph

2-1 kickdown maximum 25 mph

3-2 rollout maximum 7 mph

2-1 rollout maximum 5 mph

3-1 inhibited maximum 22 mph

2-1 inhibited maximum 15 mph

Stall speed 1675 ERPM

All shifts were smooth.

12

VII. TRANSFER CASE CALIBRATION

Vehicle drawbar with one wheel on rollers (.1 coefficient

of friction)

Front wheel 800# breakaway 800# run

Rear wheel 750# breakaway 700# run

Bench torque of SRD (shaft to shaft, SRD Housing free)

100 ft.lb.

13

INTER-OFY:ICE CORRESPONDENCE

ROY C. INGERSOLL RESEARCH CENTER

BORG-WARNER CORPORATION

DES PLAINES. ILLINOIS

TO R. E. Young DATE August 20, 1971Warner Gear - Muncie

FROMT. L. Michaels SUBJECT Military Vehicle Ml51A

Performance Analysis(3574)

Attached are the gradeability and acceleration curves for the Mi5lA militaryvehicle.

The performance requirements listed in Mr. Hamparian's letter of May 13, 1971are as follows:

1) Top speed of 60 MPH at 3650 lb. gross vehicle weight.

2) 2 1/2 MPH on a 60% grade at 3650 lb. gross vehicle weight.

3) 30 MPH on a 6 1/2% grade at 4700 gross combined weight.

These requirements are met with the BWL 9 1/2 inch converter ana 3 speed

transmission. A performance summary sheet is attached.

The Characteristic Data sheet from the U. S. Army Tank Automotive Commandlists performance specifications. The manual four speed transmission analysismatches these gradeability specifications using an overall gear and axle ef-ficiency of 70%. An overall gear and axle efficiency of 70% was used in theanalysis of the torque converter transmission also.

The performance analysis of the M35A2 Military Vehicle will follow shortly.

T. L. Michaels

TM:ld

Enclosures

cc: D. Wi CollierW. FisherR. W. HalbergG. E. KochanekH. A. McAninchCentral File

APPENDIX

Vehicle Data

U. S. Army Tank Automotive Command Truck, Utility, 1/4 ton, M151A2

Gross Vehicle Weight 3650 LBS.

Gross Combined Weight 5600 LBS.(With towed load)

Vehicle Height 5.91 FT.Width 5.35 FT.

Tire rolling radius 1.19 FT.

Engine Data

LI41 ENGINE - 73 Gross HorsepowerNet torque - 120 LB. FT. at 1800 RPMNet horsepower - 64 HP at 3700 RPM

2overned peedB 1 - 3960 RPMurve onagB-

A-Speed Manual Transmission (existing)

Transmission ratios: 5.712, 3.179, 1.674, 1.0Reverse 7.497

Transfer ratio: 1.00

Axle ratio: 4.86

3-Speed Torque Converter Transmission

Torque Converter: BWL 9 1/2 IN. 240 A/BStall K = 175Stall Torque Ratio = 1.93Curve on page B-2

Transmission ratios: 2.4, 1.46, 1.00Reverse 2.00

Transfer ratios: 2.56, 1.00

Axle ratio: 4.86

Engine and transmission

stall speed 1900 RPM

'Maximum torque converter speed ratio is .961 at the governedengine speed of 3960 RPM.

I ~ ~ 0 IT II I

0 0

E ~ - C N % %0 %0

H D Hq %A C-% C-

NO

* ~ ION

HE4 C- Ni '.ON r-I "'-4

0.0'

Cl)Cl'

BEoWQ

0 -bk tn tr-I 0 E-

I lK

-EI WT __ LGG L- cjL FY

V~tiE RAT I OS~AI F'iii .37 T4fOF

10 0i2: 1fLL-HII iK-b-- ii~'~" ~ 4: K 7,

. 1 {)> i __ [HLi-__ EM NE 'i n I4 AR RIUl1 .. L

IN

1-00 ~ ~ ~ ~ ElTh~ 5-0100 5-0000 500T j itli

IifTIAR 1HI4il C 14TN i2 7) P[': EFIE EEDIRPS113 .CA 5~

4 I I. I.- I

~~~~--- A-< r4 + i-- V -- -- -

*~*'-- ------ ---

A-1-

ou rt7 r %, AL.. LL t-t- 4 Fv**4

61zz~'~1-00*~t 5-0 1-0 000 1000500

R1l 4.1~7 ATIL..... ....... F*i

*----4-~~T L 4- -f-i

Rip AE14;V - -u- w '~!, d I ~ N4 T. :5-~ ~~piy

F _17li

VEHIW 1~h i ~ - - T' lI~ilJ

.... *: ...... K :1

, L .a k :.~..~ i ' '4

-- ,i~ -~ -. 1414.'N4R DE lopJ1~~ti~ f tK-t- li

V'pf

14 .1

L~~~~u24I ~ ~ ... t'....-. Z._:{4 L= I__ _

74'7

7- --

-L

II vv:o~o.1 .ENG'

-'K ~ T~S o ( " E S) 9

-11-NG N AT 42~

I Ni i A CO E S fq S I [ 4- -iiM LA L Sz I3

II4 VEH Wr L9G~ 5OL6j 1 LL RAE~ FT1 -1 9c1FT - 101f H.vrf~~.vt~

f -7

GA-J-- RAT -I E

- d __ i~i2

....... -

7

~~~'- gd-- t -. . - -- dlh*-

AM~0 100.0Fil I RAT

1:1 _ 44±P.l

---7- -7T - -

~~~:T f 1.I tlLA4"

* R7:AE I I1 -19[_kt~f VEH! WT L9 5Ac1 ;iJL~'E FT Hh\'L~L 41ii ' iI

- -- - -- -

~J..

-t---~-~- 2:J:7.i.L- ~7,91 ~

li 4 I r'~7

I~ ~ ~ ~ 2 ---- t-~jJ :. ~4~' [I _ - - -\

xb~47I)J ----- 1 Z--------~---:4-8i C -1 - -------- 4

f-L. N

7.w-=F0 10.0

~F'FRF1- MPin

--- .- .l . 4 ..T. .

"TilAR -I I £iv~r . ~ .1 +iLA. F .JAL AN 1 R- -

1 14 4 r FL L I 15 t

A+ ... .. 4

A. L_;~

4t A ,t1 I

~1jr7 7 T. u

Tji11~ 4~4ry .-. . ~~'4 I7

............

ITI

"1T I' .- 1

i-o5.00 10.00 50-00 iGoo Soo 5 -00

~PFF-El -y

PL 71TTFI r*II-L All

PER ii jR

31? 9- Ir I NL MW6 R ' :e 3 PEE ! o3 'J IT; 9 1 _,ES :-9 1

-L 1N RAD.FT;VTIT 3

AL , ' '' _i; i

FT: -9l -I- ST

* II C I

IL~F - *?j ~ o_J, L'' 77-

- *ir-77"-

In~ IiI

U~' T VVV1'j7~~TT~j~rf7IFI TJNE Sf IL .-.EcIIAREF fT'I WR iiVEDEWELF IIJWPE1rn 1 -.11L.

I:C1 IlO PEIOM

II -I' . t H E 31-R Z

&NO&RRM1SJ. 171 1 17'j.7 -57 " ' N

If 1ITa T 111

IL .10LIf.-AM 'I

-AXL : 1TO4 01 AXLER E PCAT

I~ L1j,

t L

TtT

17.S i Il

777 . .7

. . . . . . ...... .........

44.

.A t. L I.

_LL-

--!X77.rI

VA

0 . .~I, I

I +T7 A _ _ _ _ _4-~. : i

LONG MFG. DIVISION TORQUE CONVERTER D T

BORG-WARNER CORP. PERFORMANCE TEST N.---

DRAWING NO.- - . . - .OIL - * -

IMPELLER NO. .. . .... OLTEMPERATURE. . P. S.1. IN .,..OUT.

TURBINE NO. STALL RPM ,...L9. FT.

STATOR N~-.---.--C .. R.HR.

REMARKS... _-_.- - --

(60A0.' A-tl ve~e r' / Z 4 ?-

40-7

38- '-

34.

4 0

II-

26- 90I

777

7- -7 [-i4O>

18 50

16.! 40

S12- b20

~. .i ..~ ..... ...

0 1 .2 .3 .4 .5 .6 .7 .8 .9 1.0SPEED RATIO N0 /N1

co k

In.

iii_ N

I _ _

CO q ?>_ __ _

cxiC) 4z ~

,~' 1to

0

Q U-

unclassifiedSecurity Classification

DOCUMENT CONTROL DATA. R & D(Security classlication of title, body of abstract and indexing annotation must be entered when the overall report is claslfledj

I. ORIGINATING ACTIVITY (Corporate author) |28. REPORT SECURITY CLASSIFICATION

Warner Gear Division UnclassifiedBorg-Warner Corporation 2b. GROUP

Muncie, Indiana 473023. REPORT TITLE

Automatic Transmission With Full Time All Wheel Drive System.

4. DESCRIPTIVE NOTES (Type of report and Inclusive dates)

Final Engineering Report (June 1970 through September 1971)S. AUTHOR(S)(Firet name, middle initial, last name)

Charles JohnsonHerbert D. Hahn

6. REPORT DATE "a. TOTAL NO. OF PAGES 7b. NO, OF REFS

May 19728a. CONTRACT OR GRANT NO. 9a. ORIGINATOR'S REPORT NUMWBER(S)

DAAE07-70-C-4632b. PROJECT NO. 2969

iF. Ob. OTHER REPORT NOIS) (Any other numbere th t may be asslginedthis report)

d. TACOM Technical Report #1154010. DISTRIBUTION STATEMENT 0 Jt p .Each transmittal of this document outside the Depai fment of Defense must

have prior approval of the U. S. Army Tank-Automotive Command,ATTN: AMSTA-RHFL, Warren, Michigan 48090

II. SUPPLEMENTARY NOTES 12. SPONSORING MILITARY ACTIVITY

U. S. Army Tank-Automotive CommandWarren, Michigan

13. ABSTRACT

This report concerns the modification and evaluation of an M151A2with the installation of a three speed automatic transmission and afull time all wheel drive system. The automaticity of this totalsystem reduces driver training, increases mobility and improveshandling characteristics and drive line life.

Design layouts and detail drawings suitable for fabrication ofhardware were completed under the contract. A detailed descriptionof the system operation and performance capabilities is included inthis report.

This system is recommended for wheeled vehicle applications usinggasoline, diesel and turbine engines.

DDFoam RPLACS 00 FORM 14732 1 JAN 04. WHICH ISD v 000V 3 OBSOLETE FOR ARMY USE. UnclassifiedSecurity Classification

security Classification "

14. K oo LINK A LINK B LINK C

ROLE WT ROLE WT ROLE WT

1. Ml5lA2

2. Automatic Transmission

3. Full Time All Wheel Drive System

Security Classification

DISTRIBUTION

Commanding GeneralU. S. Army Tank-Automotive CommandWarren, Michigan

ATTN: AMSTA-REK 2

ATTN: AMSTA-RGT 10

ATTN: AMSTA-RHFL 10

ATTN: AMSTA-REB 2

Commanding GeneralU. S. Army Material CommandWashington, D.C. 20315

ATTN: AMCRD-GV 3

CommanderDefense Documentation CenterCameron StationAlexandria, Virginia 22314 20