ATTACHMENT 2

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MERCON V Specification

Automatic Transmission Fluid

Trademarked for Service in Vehicles Sold by

Ford Motor Company

MERCON® is a registered trademark of Ford Motor Company

Revised and Effective: 1 July 2004

This specification supersedes all previous editions, which become obsolete.
 MERCON®V AUTOMATIC TRANSMISSION FLUID FOR SERVICE
1. SCOPE
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The MERCON V specification establishes specific test procedures, requirements and format for presentation
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of test results that the Candidate's Finished Fluid must satisfy in order to qualify for and receive a MERCON V
License and License number.

2. APPLICATION
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Fluids, which are licensed to use the trademark MERCON V, are approved as service fluid for Ford automatic
transmissions when so specified in the vehicle Owner's Guide.

3. REQUIREMENTS
The candidate's finished fluid must be evaluated with respect to all items listed under this heading. No deviations
from or substitutions for these requirements will be accepted. The latest date of issue of the ASTM procedures will
be followed and all other testing shall be as outlined in this specification.

3.1 MISCIBILITY Page 3

3.2 VISCOSITY Page 4

3.3 COLOR Page 5

3.4 FLASH POINT Page 5

3.5 COPPER STRIP Page 5

3.6 NON-CORROSION AND NON-RUSTING PROPERTIES Page 5

3.7 CLEANLINESS LEVEL Page 5

3.8 WEAR TESTS Page 5

3.9 ANTI-FOAMING PROPERTIES Page 5

3.10 ELASTOMER COMPATIBILITY Pages 6 – 7

3.11 ALUMINUM BEAKER OXIDATION TEST (ABOT) Page 7

3.12 CLUTCH FRICTION DURABILITY Pages 8 - 13

3.13 µ-V CHARACTERIZATION (NEGATIVE SLOPE) Pages 14 - 17

3.14 ANTI-SHUDDER DURABILITY Pages 18 - 21

3.15 CYCLING TEST Page 22

3.16 SAFETY
The Finished Fluid must be safe to use and must be formulated to minimize health hazards due to toxic
or otherwise injurious ingredients. Licensee assumes all responsibility for compliance with all
applicable governmental regulations. A 16-Section ANSI Standard Material Safety Data Sheet must
accompany the License forms submitted during the License application process.

3.17 STORAGE
The Finished Fluid must not settle or separate to the extent that it would require remixing before use
and must be capable of storage without any detrimental effect.
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 3.1 MISCIBILITY TEST PROCEDURE
3.1.1 APPARATUS
Sample Jars
ASTM Cloud and Pour Point Thermometers
Refrigeration Apparatus
Metal Sample Jar Holder
Hot Oil Bath

FOR TEST PROCEDURE 3.1.2, REPORT TEST RESULTS ON FORM 1.

3.1.2 PROCEDURE
A. Shake candidate's finished fluid sample well and fill four sample jars (3 jars to 4 cm and 1 jar to 8 cm).

B. Fill the three jars containing 4 cm of the candidate's finished fluid to the 8 cm mark by adding one of each
of three reference fluids (Exxon FN 1975, Petro-Canada RDL 3208E and Shell M1375.3) to each jar.
Label sample jars.

C. Mix thoroughly.

D. Observe and record initial color and visible separation per ISO 2049/ASTM D1500. (Limits 6.0 – 8.0)

E. Insert low-temperature ASTM cloud and pour point thermometers in each sample.

F. Place samples in metal holder in refrigeration compartment at -55° C.

G. When sample is at -20° C, remove and tilt jar to horizontal position. If movement is observed in first 5
seconds, replace in refrigerator.

H. Lower temperature of sample 5° C and repeat item G above for each descending increment of 5° C, until
no motion of fluid is observed in 5 seconds. Record temperature 5° C higher as pour point.

I. Remove sample and allow it to thaw.

J. Observe for separation when cloudiness has disappeared. Record observations.

K. After samples have reached room temperature, remove low-temperature thermometers and place
samples in oil bath.

L. Heat bath up to 192° ± 2° C and hold for 4 hours. Continue heating to 232° ± 2°C and allow sample
temperature to reach equilibrium.

M. Remove samples, cork and allow the samples to reach room temperature.

N. Report color of fluid at room temperature. (Limits 6.0 – 8.0)

O. Place sample in cold compartment at the pour point of the sample for 18-24 hours.

P. Remove and allow the sample to thaw.

Q. Observe and record separation and color when cloudiness has barely disappeared. (Limits 6.0 – 8.0)

R. Observe and record separation and color when sample has reached room temperature. (Limits 6.0 – 8.0)

*Note: Any separation is not acceptable.

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 3.2 VISCOSITY TEST PROCEDURE
Note: Each test must be conducted on NEW FLUID. Perform 2 tests at each temperature and report both results.
Report to nearest 0.1°C.

FOR TEST PROCEDURES 3.2.1 – 3.2.8, REPORT TEST RESULTS ON FORM 2.

Limits Density (gm/cc)
2
3.2.1 KINEMATIC VISCOSITY AT 100°C (ISO 3104/ASTM D 445) 6.8 mm /s min. R&R

3.2.2 BROOKFIELD VISCOSITY AT -20°C (ASTM D 2983) 1500 mPa.s max. R&R

3.2.3 BROOKFIELD VISCOSITY AT -40°C (ASTM D 2983) 9000 ± 4000 mPa.s R&R

3.2.4 SHEAR STABILITY (ISO 3104/ASTM D 445):

2
Kinematic Viscosity at 100°C New Fluid 6.8 mm /s min.
2
Kinematic Viscosity at 100°C after 20 hrs. KRL 6.0 mm /s min.
Kinematic Viscosity at 100°C after 40 hrs. KRL R&R

3.2.5 APPARENT VISCOSITY at 150° C:

Undegraded, 200/s shear rate, ULSV R&R
6
Undegraded, 1 X 10 /s shear rate, UHSV (ASTM D 4683) R&R
Degraded*, 200/s shear rate, DLSV R&R
6
Degraded*, 1 X 10 /s shear rate, DHSV (ASTM D 4683) 2.6 mPa.s min.
* Note: Fluids are degraded by KRL, duration C (20 hours) - per CEC L45-T-93

Note: Construct Viscosity Loss Trapezoid using data from 3.2.5. Plot viscosities as the linear ordinate
and shear rates as the logarithmic abscissa per Chart 1 below.
CHART 1 – SCHEMATIC OF VISCOSITY

U LSV
Viscosity, cP

UHSV

D LSV
DHSV

2 6
10 10
S h e a r ra te , 1 /s e c

3.2.6 APPARENT VISCOSITY at 100°C:

6
Degraded KRL, 1 X 10 /s shear rate, DHSV, min. (ASTM D 4683) 5.4 mPa.s min.

3.2.7 VISCOSITY CHANGE AT -40° C AFTER MODIFIED NOACK 2000 mPa.s max.
(150°C, 2 hrs.) (New Fluid Results from 3.2.3) (ASTM D2983)

3.2.8 EVAPORATION LOSS (Modified NOACK Test, 150°C, 2 hrs.) 5% difference from new oil max.
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 3.3 – 3.7 TEST PROCEDURES
FOR TEST PROCEDURES 3.3 – 3.7, REPORT TEST RESULTS ON FORM 3.
Limits
3.3 COLOR (ISO 2049/ASTM D 1500) Red 6.0 - 8.0

3.4 FLASH POINT (ISO 2592/ASTM D 92) 177°C min.

3.5 COPPER STRIP (ISO 2160/ASTM D 130),3 hrs. at 150°C) 1b max.

3.6 NON-CORROSION AND NON-RUSTING PROPERTIES No visible rust

(ASTM D 665 - PROCEDURE "A", 24 hrs.)

3.7 CLEANLINESS LEVEL ISO Cleanliness Code (SAE J-1165 / ISO 4402) R&R

3.8 WEAR TESTS

FOR TEST PROCEDURES 3.8.1 – 3.8.5, REPORT TEST RESULTS ON FORM 4.
REFERENCE RUNS: A reference run is required when internal components of the test device are replaced or repaired
(excluding electrical components) or after every eighth candidate run. The reference fluid is Petro-Canada RDL3208E
tested under standard test conditions noted in this specification.
Note: Vane Pump reference runs are not required.
Limits
3.8.1 VANE PUMP WEAR TEST, wt. loss, 10 mg max.
(Modified ASTM D 2882 at 80° ± 3°C, 6.9 MPa)

3.8.2 FZG GEAR WEAR TEST, Load Stage Pass (LSP) 11 LSP min.
(Modified ASTM D 5182, 1450 RPM, 15 min. at 150°C start temp.)

3.8.3 FOUR-BALL WEAR TEST 0.61 mm max.

(Modified ASTM D 4172, 600 RPM, 2 hrs., 40 Kg load)
Average of 2 Runs Wear Scar at 100°C
Average of 2 Runs Wear Scar at 150°C

3.8.4 FALEX EP TEST (METHOD B) (ASTM D 3233) 1650 kg min.

Average of 2 Runs No Seizure Load at 100°C – 1 min.
Average of 2 Runs No Seizure Load at 150°C – 1 min.

3.8.5 TIMKEN WEAR TEST

(Modified ASTM D 2782 20 kg load, 150°C, 10 min.) (Average of 2 runs) 0.6 mm burnish max. & NO scoring

3.9 ANTI-FOAMING PROPERTIES

FOR TEST PROCEDURES 3.9, REPORT TEST RESULTS ON FORM 5.
3.9.1 DIFFUSER CHARACTERISTICS (ASTM D 892) (Only use a Norton diffuser.)
Maximum Pore Diameter (ASTM D 892 Appendix A1.3), Permeability (ASTM D 892 Appendix A1.3.2), and
Diffuser Identification
Characteristics must be evaluated on new diffusers and after every tenth usage. Data must be
reported on quarterly QC charts.

3.9.2 TEST CRITERIA

Foaming tendency at end of 5-minute blowing period (Sequence 1-3) 50 ml max.
Foaming tendency at end of 5-minute blowing period (Sequence 4) 100 ml max.
Foam stability at end of 1 minute settling period (Sequence 1-4) 0 ml max.
* For Sequence 4 Operation: (150° ± 3°C) (200 ml/min. air)
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 3.10 ELASTOMER COMPATIBILITY TEST PROCEDURE
FOR TEST PROCEDURE 3.10, REPORT TEST RESULTS ON FORM 6.

3.10 ELASTOMER TESTS FOR CANDIDATE FINISHED FLUID

[Link] Sixteen strips of each elastomer (cut per ASTM D 471) will be immersed in 4 tubes (4 strips per test tube)
containing each of the reference fluids (noted below), as shown in Figure 2 of ASTM D 471. Three tubes
contain the reference fluids and the other tube contains the candidate finished fluid.
NOTE: EACH TYPE OF ELASTOMER MUST BE TESTED IN THE FOLLOWING REFERENCE FLUIDS:
ASTM #1, ASTM #903 AND PETRO-CANADA RDL-3208E.

[Link] Samples will be immersed per ASTM D 471, paragraph 7.1 for the times and temperatures specified below
in Table I. Limits for volume, hardness, tensile strength and elongation for each elastomer are also
specified below in Table I.

[Link] Report data for Volume Change, Tensile Strength Change and Elongation Change according to ASTM D
471. Report data for Hardness Change according to ASTM D 2240.

TABLE I – ELASTOMER TEST CONDITIONS AND CRITERIA

Tensile
Time Candidate Fluid Volume Hardness Elongation
Elastomer Material Strength
(hours) Temperature Change Change Change
Change

ATRR-101 NBR (Nitrile) 168 150° ± 1° C - 3 to 4% 0 to 10 R & R* R & R*

ATRR-201 ACM (Polyacrylate) 70 163° ± 1° C 0 to 6% ±5 R & R* R & R*

ATRR-300 VMQ (Silicone) 240 163° ± 1° C 20 to 48% -15 to -40 R & R* R & R*

ATRR-400 FKM (Fluoroelastomer) 240 163° ± 1° C 0 to 4% ±8 R & R* R & R*

ATRR-500 AEM (Ethylene Acrylic) 240 163° ± 1° C 5 to 15% ±5 R & R* R & R*

ATRR-600 CSM 168 150° ± 1° C 5 to 35% -30 to 0 R & R* R & R*

(Chlorosulfonated Polyethylene)

ATRR-700 HNBR 168 150° ± 1° C - 2 to 4% 0 to 5 R & R* R & R*

(Hydrogenated Nitrile)
*R & R = Rate and Report

3.10.2 ELASTOMER REFERENCE MATERIAL CERTIFICATION (Laboratory use only):

Data from each batch of elastomer to be used for these tests must first be submitted by the supplier for approval
to FSATFC and must contain the following information:
A. Formulation
B. Rheometer curve
C. Original properties (ASTM D 412): Tensile Strength, Elongation and Durometer (ASTM D 2240)
D. Properties after aging the elastomers in the following fluids, ASTM #1, ASTM #903, Exxon FN 1975, Petro-
Canada RDL-3208E and Shell M1375.3: Hardness Change, Volume Change, Tensile Strength Change and
Elongation Change.

After receiving written approval from FSATFC, the batch will be released to the laboratory. Fluid compatibility
characteristics of each batch of all reference elastomers are to be determined by the following procedure before
qualifying finished fluids.

Each laboratory shall run 12 test specimens using the following reference elastomers, ATRR 101, 201, 300, 400,
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 500, 600 and 700 (6 tubes of each elastomer) and the following reference fluids, ASTM # 1, ASTM # 903, Exxon FN
1975, Petro-Canada RDL-3208E and Shell M1375.3. These tests shall be conducted in apparatus that will be used
in subsequent testing of candidate finished fluids. The results of these tests shall be submitted to the FSATFC for
evaluation. If accepted, the results will be the reference data for each laboratory.

Ford will establish minimum and maximum limits for volume change, hardness change, elongation change and
tensile strength change using the above test results.

The following data will be recorded for each of the above tests: elastomer batch numbers, the date of testing,
reference fluid acquisition date, the volume change, hardness change, elongation change and tensile strength
change.

3.11 ALUMINUM BEAKER OXIDATION TEST (ABOT)

FOR TEST PROCEDURE 3.11, REPORT TEST RESULTS ON FORM 7.

3.11.1 ABOT testing is conducted according to the Ford Corporate Procedure. For questions regarding the test
procedure, please contact FSATFC. The test acceptance criteria is stated in Table II.

TABLE II – ABOT TEST CRITERIA

Item Test Time (Hours) Test Limit

Pentane Insolubles 300 Less than .35%

TAN Change 300 3.5 max.

Diff. IR, Absorbance per cm path length 300 30 max.

% Viscosity Increase, 40°C 300 25% max.

Weight Loss of Lead Coupon 100 3% max.

Copper Strip Rating 50 3b max.

300 3b max.

Aluminum Strip Rating 300 No varnish

Sludge 300 No sludge

Viscosity, -40°C 300 Rate and Report

Calculated % Weight Loss 300 Rate and Report

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 3.12 CLUTCH FRICTION DURABILITY
FOR TEST PROCEDURE 3.12, REPORT TEST RESULTS ON FORMS 8 AND 9. ATTACH ALL DATA INCLUDING
CHARTS, GRAPHS AND TORQUE TRACES.

TEST DESCRIPTION: The friction durability procedure intent is to establish data to evaluate durability performance of the
fluid/friction interface. The durability procedure is run on a SAE #2 machine that meets the guidelines/specifications as
outlined in procedure SAE J286. Run one pack with each friction material listed below for 30,000 cycles to test durability
according to the following procedure. One pack consists of four steel plates and two friction plates arranged according to
Figure 1.
Friction Material: SD-1777 Friction Material: D-0530-31 Steel Plates
Part No.: XP-00312996-AA1 Part No.: XP-00312998-AA1 Part No.: XP-143218

Friction material available from: Friction material available from: Steel plates available from:
Borg Warner Corporation Dynax International Corp. Steel Parts Corporation
TH
700 S. 25 Avenue 47805 Galleon P.O. Box 700
Bellwood, IL 60104 Plymouth, MI 48170 Tipton, IN 46072-0620
Attn: Bruce Clay (708) 547-2744 Attn: Keith Barker (734) 751-0010 Attn: Bob Alonzo (317) 675-2191

3.12.1 PLATE TEMPERATURE MEASUREMENTS (See Section [Link] prior to machining holes for thermocouples.)
Temperatures are to be measured for plates 1 and 3 (see Figure 1) with type J thermocouples or similar
temperature measuring devices (TMD). One thermocouple is to be located in each steel plate. The holes are made
using electro-discharge machining (EDM) or other suitable technique, are 0.58 mm in diameter and located at mid
separator plate thickness. The holes are 13 mm deep from the root of the spline tooth to place the thermocouple
junction at the mean friction radius and are placed at the 12 o'clock position in the test head. The TMD should be
fitted to touch the bottom of the manufactured hole for good thermal contact and cemented to prevent movement
during plate insertion or during testing.

FIGURE 1 – PACK CONFIGURATION

Plate Number Cover (Front) Side

Steel 1

Friction 2

Steel 3
Steel 4

Friction 5

Steel 6
Motor (Back) Side

3.12.2 CLEANING PROCEDURE

Prior to each test, the fixture must be cleaned. Remove the front cover, the spacer, retainer ring and hub. These
parts are cleaned with Stoddard solvent (low flash point), scrubbed with a non-metallic bristle brush or non-metallic
scouring pad and rinsed. The inside of the test housing, attached ports and thermocouple connections are flushed
with Stoddard solvent using a squeeze bottle. Thoroughly clean all crevices and ports in the housing where lubricant
is likely to be trapped. If pump is used, clean all internal pump components using stoddard solvent and a non-
metallic brush. Flush all lines from test head to pump with stoddard solvent. Air blow-dry the cleaned parts and test
housing.

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3.12.3 ASSEMBLY PROCEDURE
[Link] Inspect rotating shaft seal for deterioration and replace if necessary. Indication of seal failure or loss of
flexibility is the escape of air past the seals. If this seal is replaced, also replace lip seals.

[Link] Install clutch plate hub, snap ring, and clutch plate retainer.

[Link] Inspect clutch plates prior to testing using the following procedure before the plates are machined for
thermocouple installation.
A. Find the thickest spot of each plate and arrange the plates so the thick spots are distributed around the pack.

B. Identify each plate by marking the top tooth with a number, one through six, in the sequence shown in
Figure 1. The number on the steel plates is to be put on the rounded side. This number will be at the
top and facing the cover when each plate is installed for test.

C. Mark a tooth at approximately 120° each way around from the numbered tooth on each plate.

D. Measure and record the average overall pack thickness at three places (at the numbered teeth, at 120°
and at 240°) under a 14 kg load.

E. At each of the three locations, 120° apart, measure at two places, one near the inside, and one near the
outside diameter. These measurements will be labeled "initial".

F. Use a micrometer and keep the entire anvil within the friction contact area for each measurement.

G. Following completion of the test, repeat the measurements in steps D, E and F in the same order and at
the same places, beginning at the numbered tooth. These measurements are labeled "final".

H. Subtract the "final" measurements from the "initial" measurements. Wear limit at any of the six places is
0.152 mm. Average wear per plate is not to exceed 0.076 mm.

[Link] Presoak clutch friction plates in candidate test fluid for 5 minutes minimum and then install clutch plates in
the test head in the order prescribed with plate number facing the cover.

[Link] Install plates into test head. The sump thermocouple is to be located at the midpoint of the back-to-back
plates of the pack.

[Link] Install two spacers only between the cover and the outermost clutch plate in order to locate the sump
thermocouple at the center of the test pack.

[Link] Check clutch plate pack free movement. Clearance is 0.70 ± 0.13 mm. This measurement, made with a
depth micrometer, is made between the head and outermost clutch plate while the pack is pressed into the
head with finger pressure (about 1 kg) at the sites of measurements.

[Link] Install sump thermocouple between the 4 and 5 o'clock position to within 1.0 mm of steel clutch plate
annulus O.D. (without touching clutch plate).

[Link] Install new O-rings on cover, if necessary.

[Link] Attach cover and fasten with cover retainer.

3.12.4 LUBRICANT INSTALLATION

[Link] Attach reservoir line to housing port at 12 o'clock position. Close all other housing ports. The fill volume is
305 ± 5 mL. Open the valve at the 11 o'clock position to allow air venting during filling. Close this valve
when oil begins to overflow.

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3.12.5 TEST START-UP
[Link] Connect instrumentation for measuring torque, pressure, motor-speed, and thermocouple temperature.
Calibrate torque, pressure, and speed signals. (Note: If compression type load cell is used, calibrate
torque with lever-arm tare included in calibration.)

[Link] Set apply pressure to 275 ± 5 kPa at a rate of 0.15 ± 0.02 seconds to full apply pressure. Apply pressure
should reach full apply in a linear manner.

[Link] Set release pressure to 75 kPa min.

[Link] Open cooling fluid valve.

[Link] Set timer to provide the following test-cycle sequence as shown in Table III.

TABLE III - SEQUENCE

Event Duration (Seconds) Total Time (Seconds) Operation

1 10 (T1)* 0-10 HS (High Speed) motor on, force released

2 2 (T1+T2)* 10-12 Motor off, force applied

3 3 (T4)* 12-15 Motor off, force released

4 0.5 15-15.5 SD (Static Motor) on to engage static drive

5 5 15.5-20.5 SD motor off, force released

6 0.5 20.5-21 SD motor off, force applied

7 5 21-26 SD motor on, force applied

8 5 26-31 SD motor off, force released

*Reference SAE Friction Nomenclature Specification (SAE J1646)

[Link] Start temperature recorder.

[Link] Start timer (this engages motor).

[Link] Check for leaks, operation of transducers and cycling event times.

3.12.6 TEST START-UP AFTER UNSCHEDULED SHUTDOWN

[Link] Determine and correct cause of shutdown. Record length of time of shutdown, reason for shutdown and
reasoning for continuing testing. Questions about unusual circumstances require discussion with FSATFC.

[Link] Repeat Test Start-Up sequence 3.12.5.

3.12.7 TEST OPERATION

[Link] Repeat test cycle sequence for 30,000 cycles. The motor RPM should be 3,600 and the energy should be
20,740 ± 200J.

[Link] Maintain fluid temperature during operation at 135° ± 3°C.

[Link] Record Static Breakaway torques after clutch pack has been released (allowed to separate) for a 5 second
soak time. Static breakaway speed is 4.37 ± 0.1 rpm.
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 [Link] Two static breakaway measurements are required. Measure the first static breakaway 0.25 seconds after
beginning of zero time. Zero time begins at threshold torque plus 5 Nm positive torque. The first static
breakaway torque shall be the mean of torques obtained during 50 ms interval centrally located about the
0.25 ± 0.02 second point. The second static breakaway torque is the maximum torque measured at the
beginning of the static breakaway condition. Report the first torque as well as the maximum torque
measured between zero time and the 0.25 ± 0.02 second time. (See Figure 2)

3.12.8 TEST RESULTS REQUIRED FOR REVIEW

[Link] Record torque, apply pressure and motor speed during test cycle sequence at intervals indicated in Table
IV.
[Link] Friction Data for torque cycles specified in Table IV.

[Link] Record apply pressure and motor speed at 5 cycles to confirm proper test operation.

[Link] Record temperatures continuously for bulk (sump), plate 1 and plate 3. Plot temperature for both bulk fluid
and plates specified. (Attach plots to Form 9.)

[Link] Coefficient of friction shall be calculated using the following equation and constants:

T T = Torque (Nm)
µ = P = Pressure (kPa)
PARN A = Apply Piston Area (m²)
R = Mean Friction Radius (m)
N = Active Friction Surfaces
Apply Piston Area should be 0.015 m²
Mean Friction Radius = 0.059 m
Active Friction Surfaces = 4

[Link] Record the following information after 30,000 cycles: Viscosity at 100° C, Viscosity at -40° C, TAN
and Diff. IR.

[Link] Graph coefficient vs. cycles for static breakway, dynamic and low speed dynamic engagements. (Attach
graphs to Form 9.)

[Link] Graph stop times vs. cycles (Attach graph to Form 9.)

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 TABLE IV – TEST RESULTS REQUIRED FOR REVIEW

Perform evaluation at the following schedule:

MIDPOINT LOW SPEED STATIC

E/M RATIO B/M RATIO
LIMITS / CYCLES DYNAMIC DYNAMIC BREAKAWAY STOP TIME
COEFFICIENT (S1/D) (S2/D)
COEFFICIENT COEFFICIENT
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MERCON V Limits BW: 0.140 – 0.170 BW: 0.135 – 0.175 BW: 0.65–0.155 BW: 0.90 – 1.05 BW: R&R BW: 0.70 - 0.90

Dynax: R & R Dynax: R&R Dynax: R&R Dynax: R&R Dynax: R&R Dynax: R&R

M = µd 1800 E = (φ-0.05)µd max* B = 0.25µs 4.37 E/M B/M t

25 R&R R&R

100 R&R R&R R&R

200 R&R X R&R X R&R

400 X X X X R&R X

FROM 400 TO 1000 X X X X X X

CYCLES AT 200 CYCLE
INTERVALS

FROM 1000 TO 30000 X X X X R&R X

CYCLES AT 2000 CYCLE
INTERVALS

NOTE: Data required at cycles indicated by x. R & R = Rate and Report. Reference SAE Friction Nomenclature Specification (SAE J1646).

3.12.9 TEST CRITERIA

[Link] All required coefficients shall be calculated using the mean of 5 measured torque values taken ± 2 cycles
around the specified cycle. The maximum and minimum torques of each range are to be reported with
the coefficient of the specified cycle.

[Link] Between 400 and 30,000 cycles, all midpoint dynamic coefficients at 1800 RPMs shall fall within a range
specified below. Midpoint dynamic torque is to be a mean of torques obtained during the 50 ms interval
centrally located about the 1800RPM speed. See Figure 2.
µd1800 for SD-1777 = 0.140 - 0.170 µd1800 for D-0530-31 = Rate & Report
[Link] Between 400 and 30,000 cycles of operation, all low speed dynamic peak coefficients (calculated from the
dynamic torque trace) shall fall within a range specified below. The low speed dynamic measurement shall
be the highest value for torque obtained within the last 50 ms of the torque measurement. The time of the
measurement must be reported. See Figure 2.
φ-0.05µd max for SD-1777 = 0.135 - 0.175 φ-0.05µd max for D-0530-31 = Rate & Report

[Link] Between 400 and 30,000 cycles of operation, all static breakaway coefficients must fall within a range
specified below. Static breakaway torques must be obtained after the clutch pack has been opened for 5
seconds following the dynamic engagement to allow the friction surfaces to attain temperature
equalization. The static breakaway torque values are to be measured at 0.25 seconds after the beginning
of the static engagement. See Figure 2.
0.25µs 4.37 for SD-1777 = 0.65 - 0.155 0.0µs 4.37 for SD-1777 = Rate & Report

µs 4.37 for D-0530-31 = Rate & Report

0.25 0.0µs 4.37 for D-0530-31 = Rate & Report

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 [Link] Between 400 and 30,000 cycles of operation, all ratios of the low speed dynamic coefficient to the
midpoint dynamic coefficient E/M, both obtained from the same dynamic engagement trace, shall fall
within a range specified below. Ratios between the static breakaway coefficient and the mid-point
dynamic coefficient B/M are to be "rate and report". See Figure 2.
(φ - 0.05) µd max (0.25) µs 4.37
E/M = --------------- = 0.90 - 1.05 B/M = --------------- = Rate & Report
(µd 1800) (µd 1800)

E/M and B/M for D-0530-31 is Rate & Report

[Link] Between 400 and 30,000 cycles of operation, all stop times must fall within a range specified below. See
Figure 2.
For SD-1777: 0.70 to 0.90 seconds. For D-0530-31: Rate & Report.

FIGURE 2 – STATIC AND DYNAMIC TRACE INFORMATION

D E

A = Low Speed Dynamic Torque Time D = Max Static Torque

B = Mid-Point Dynamic Torque E = 0.25 Static Torque
C = Low Speed Dynamic Torque Note: The "D" value is Rate and Report

3.12.10 REFERENCE FRICTION TEST (Use Form 9)

th
Reference packs must be run for initial approval of each stand and after every 8 candidate test or following
replacement or repair of major stand components in the following sequence:
1. After first set of 8 candidates has been run, use Petro-Canada RDL-3208E with SD-1777 friction material for the
reference run,
2. After second set of 8 candidates has been run, use Shell M1375.3 and ExxonMobil FN 1975 with SD-1777
friction material for the reference runs (total of 2 tests).
th
Continue alternating the fluids mentioned above for every 8 candidate. The initial qualification run and every 4th
reference run must be done at 20,000 cycles. All other reference runs may be 4,000 cycles.

Provide most recent reference pack data at 4,000 or 20,000 cycles: Static Breakaway Torque, Static Breakaway
Coefficient, Mid-Point Dynamic Torque, Mid-Point Dynamic Coefficient, Low Speed Dynamic Torque, Low Speed
Dynamic Coefficient, Stop Time, E/M Ratio, B/M Ratio, Test Machine Number and Pack Identification Number.

Provide cumulative data plots at 4,000 and 20,000 cycles of Static Breakaway Torque, Static Breakaway Coefficient,
Mid-Point Dynamic Torque, Mid-Point Dynamic Coefficient, Low Speed Dynamic Torque, Low Speed Dynamic
Coefficient, Stop Time, E/M Ratio, and B/M Ratio.

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Ford Motor Company Page 13 of 22 MERCON V Specification
 3.13 µ-V CHARACTERIZATION (NEGATIVE SLOPE)
FOR TEST PROCEDURE 3.13, REPORT TEST RESULTS ON FORM 8. ATTACH ALL DATA INCLUDING CHARTS,
GRAPHS AND TORQUE TRACES.

TEST DESCRIPTION: The µ-V characterization procedure intent is to evaluate low-speed anti-shudder performance. The
µ-V characterization procedure is run on a SAE #2 machine that meets the guidelines/specifications as outlined in Procedure
SAE J286. This test is run on a modified SAE #2 machine with a variable speed drive system capable of producing stable
torque values in 1-300 rpm range and 680 Nm torque, a pump with a variable flow rate of 1.5 to 2.3 liters per minute, and a
fixed fluid capacity of 300 ml.

Run one pack at the conditions described below. A pack consists of two steel separator plates and one friction plate (see
Figure 3). The friction plate is rotated during the test and the separator plates are stationary. The driving splined hub is
sealed at the O.D. to force all flow of pumped fluid across the faces from the center of the hub and through the grooves of
the friction material. All packs will be run after receiving a 30-minute break-in per procedure in Table V. Torque and speed
conditions are interactive and a feedback system must be in place. The durability is conducted using torque control and the
µ-V data is acquired using speed control.
Friction Material: SD-1777-C Steel Plates
Part No.: XP-00312997-AA1 Part No : XP-143218

Friction material available from: Steel plates available from:

Borg Warner Corporation Steel Parts Corporation
TH
700 S. 25 Avenue P.O. Box 700
Bellwood, IL 60104 Tipton, IN 46072-0620
Attn: Bruce Clay (708) 547-2744 Attn: Bob Alonzo (317) 675-2191

3.13.2 PLATE TEMPERATURE MEASUREMENTS (See Section [Link] prior to machining holes for thermocouples.)
Temperatures for plate 1 and 3 (see Figure 3) are to be measured with two type J thermocouples or similar
temperature measuring devices (TMD). Two thermocouples are located in each steel plate, 180° apart. The holes
are made using electro-discharge machining (EDM) or another suitable technique, are 0.58 mm in diameter and
located at mid separator plate thickness. The holes are 13 mm deep from the root of the spline tooth to place the
thermocouple junction at the mean friction radius and the thermocouples are placed at the 3 and 9 o'clock position
in the test head. The TMD should be fitted to touch the bottom of the manufactured hole for good thermal contact
and cemented to prevent movement during plate insertion or during testing.

3.13.3 CLEANING PROCEDURE - Refer to 3.12.2.

3.13.4 ASSEMBLY PROCEDURE

[Link] Inspect rotating shaft seal for deterioration and replace if necessary. Indication of seal failure or loss of
flexibility is the escape of air past the seals. If this seal is replaced, also replace lip seals.

[Link] Install clutch plate hub, snap ring, and clutch plate retainer.

[Link] Inspect clutch plates prior to testing using the following procedure before the plates are machined for
thermocouple installation.
A. Find the thickest spot of each plate and arrange the plates so that the thick spots are distributed around
the pack.

B. Identify each plate by marking the top tooth with a number, one through three in the sequence shown in
Figure 3. The number on the steel plates is to be put on the rounded side. This number will be at the
top and facing the cover when each plate is installed for test.

TO COMPLETE THE PLATE INSPECTION AND MEASUREMENT PROCEDURE, REFER TO [Link] C – H.

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Ford Motor Company Page 14 of 22 MERCON V Specification
 Figure 3 - µ-V Characterization (Negative Slope) Plate Configuration

Plate Number Cover (Front) Side

Steel 1

Friction 2

Steel 3
Motor (Back) Side

[Link] Presoak clutch friction plates in candidate test fluid for 5 minutes minimum and then install clutch plates in
the test head in the order prescribed with plate number facing the cover.

[Link] Install one spacer between the piston and the inner separator plate and one between the cover and the
outer separator plate.

[Link] Install new O-rings on cover, if necessary.

[Link] Attach cover and fasten with cover retainer.

3.13.5 LUBRICANT INSTALLATION

[Link] Attach oil pump outlet line to center of cover and attach inlet line to fluid outlet on head. Close all other
housing ports. Fill pump with 300 ml of fluid and circulate through system.

3.13.6 TEST START UP

[Link] Connect instrumentation for measuring torque, pressure, motor-speed, and temperature. Calibrate
transducers and thermocouples. (Note: If compression type load cell is used, calibrate torque with
lever-arm tare included in calibration.)

[Link] Cycle piston pressure five times from 0 kPa to 310 ± 10 kPa (3 seconds on, then 3 seconds off) to promote
oil saturation throughout the friction material.

[Link] Break in using the parameters in Table V.

TABLE V – BREAK-IN AT 100 RPM, 100° ± 2°C, AND 1.9 L/M ± 0.1
Event Duration(Min.) Accumulated Time (Min.) Pressure

1 10 10 104 kPa, force applied

2 1 10-11 0 kPa, force released
3 10 11-21 104 kPa, force applied

4 1 21-22 0 kPa, force released

5 10 22-32 104 kPa, force applied

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Ford Motor Company Page 15 of 22 MERCON V Specification
 [Link] Run test to the test-cycle sequence in Table VI.

TABLE VI – µ-V TEST PARAMETERS

CONTROLLED APPLY TORQUE 90 Nm

SLIDING SPEED 160 rpm

DURATION 115 hours minimum

TEMPERATURE 100° ± 2° C for Sump

FLOW RATE 1.9 ± 0.1 L/m at 100° ± 2° C

[Link] Start recording devices. Check for leaks and check operation of transducer, pump and event timer.

3.13.7 DATA COLLECTION

[Link] Record plates and head inlet oil temperature, torque, apply pressure, and motor speed during test cycle
sequence at intervals and conditions indicated in Table VII.

TABLE VII - TYPICAL CONDITIONS FOR µ-V DATA COLLECTION

OIL TEMPERATURE 100° C Sump

APPLY PRESSURE 345 kPa

SHAFT SPEED 2, 6, 10, 14, 20, 40, 60, 80, 120 rpm or continuous mode

DURATION 2.0 sec.@ each speed (zero duration for continuous runs)

INTERVAL - HRS. 0, 15, then 10 hr. increments to 115 hours

For incremental speed data acquisition: At the 1.90 sec point within the 2.0 sec window
at each specified speed; torque must be stable.
Alternate method: Continuous torque recording during change of speed from 0 to 120
DATA ACQUISITION
and back to 0 rpms two consecutive times then reporting the average torque for the two
readings at the specific speeds noted above obtained on the 120 to 0 (reducing speed)
parts of the curves.

[Link] Prepare plots of torque as a function of rpm while performing the µ-V portion of the test and piston
pressure as a function of time for the durability portion of the test.

[Link] Plot the torque as a function of slip speed for all time increments. If the continuous slip technique is used,
provide torque vs. slip speed curves for the increasing and the decreasing speed cycle. Calculate the
coefficients of friction for these torques using the equation below. Plot torque and coefficients of friction
versus slip speed for the data generated. Also plot the temperature recorded for the steel plates during
durability runs. Record the temperatures and pressures continuously, but report the temperatures and
pressures at 1 minute before each hour interval during each 10-hour period. Plot the piston apply pressure
as a function of the time in hours at one hour intervals for the entire durability test.
Coefficient of friction shall be calculated using the following equation and constants:
T T = Torque (Nm)
µ = P = Pressure (kPa)
PARN A = Apply Piston Area (m²)
R = Mean Friction Radius (m)
N = Active Friction Surfaces
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Ford Motor Company Page 16 of 22 MERCON V Specification
 Apply Piston Area should be 0.015 m²
Mean Friction Radius = 0.059 m
Active Friction Surfaces = 2

[Link] Calculate ratio of 2 rpm to 20 rpm torques, identified as R1 and the ratio of 40 to 120 rpm torques, called
R2. Both ratios exceeding 1.00 at 100°C is defined as negative slope.

[Link] When negative slope is acquired per paragraph [Link], continue for one additional 10 - hour increment
for verification. Negative slope is verified when both R1 and R2 remain negative for two10 - hour sequential
increments. When negative slope is verified, the failure time requested is that of paragraph [Link].

[Link] Prepare a graph using the following information and calculations:

A. Using the pressure data from the durability determine the slope of the pressure differences as a
function of the time using the least squares fit of two data points.

B. Plot the slope of the pressure difference with respect to time for the entire run until negative slope has
been established per paragraph [Link] and [Link].

C. Using this graph, the increase of dP/dt (change in pressure/change in time) must occur after 115 hours.
In the event this graph does not rise, the criteria for paragraph [Link] and [Link] will rule.

3.13.8 REFERENCE RUNS

th
Perform a reference run after every 8 candidate with Shell M1375.3 as the reference fluid.

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Ford Motor Company Page 17 of 22 MERCON V Specification
 3.14 ANTI-SHUDDER DURABILITY
FOR TEST PROCEDURE 3.14, REPORT TEST RESULTS ON FORMS 8 AND 10. ATTACH ALL DATA INCLUDING
CHARTS, GRAPHS AND TORQUE TRACES.

TEST DESCRIPTION: The anti-shudder procedure intent is to evaluate anti-shudder performance with time and fluid aging.
The anti-shudder durability test is run on a modified SAE #2 machine that meets the guidelines/specifications as outlined in
Procedure SAE J286.

3.14.1 TEST PROCEDURE

A two liter heated reservoir is attached to the test head of SAE # 2 machine. Fluid volume of about 1000 ml's/min is
pumped into the test head. A copper coupon (area =30 cm2) is immersed in the test fluid and air is bubbled into the
test head at a rate of 50 cc/min through a metallic diffuser.
Run one pack at the conditions described below. A pack is considered to be two steel separator plates and one
friction plate (see Figure 3). The friction plate is rotated during the test and the separator plates are stationary. All
torque information must be obtained using digitized data acquisition. All packs will be run after completing the break-
in procedure (Table VIII). Torque and speed conditions are interactive and a feedback system must be in place.
Friction Material: D-531-70H Separator Plates
Part No.: XP-00312999-AA1 Part No : XP-143218

Friction material available from: Separator plates available from:

Dynax International Corp. Steel Parts Corporation
47805 Galleon P.O. Box 700
Plymouth, MI 48170 Tipton, IN 46072-0620
Attn: Keith Barker (734) 751-0010 Attn: Bob Alonzo (317) 675-2191

3.14.2 PLATE TEMPERATURE MEASUREMENTS Refer to 3.12.1.

3.14.3 CLEANING PROCEDURE Refer to 3.12.2.

3.14.4 ASSEMBLY PROCEDURE

[Link] Inspect rotating shaft seal for deterioration and replace if necessary. Indication of seal failure or loss of
flexibility is the escape of air past the seals. If this seal is replaced, also replace lip seals.

[Link] Install clutch plate hub, snap ring, and clutch plate retainer.

[Link] Refer to [Link].

[Link] Presoak clutch friction plates in candidate test fluid for 5 minutes minimum and then install clutch plates in
the test head in the order prescribed with plate number facing the cover.

[Link] Install one spacer between the piston and the inner separator plate and one between the cover and the outer
separator plate.

[Link] Install new O-rings on cover, if necessary.

[Link] Attach cover and fasten with cover retainer.

3.14.5 LUBRICANT INSTALLATION

[Link] Attach pump outlet line to bottom of test head and attach inlet line to heated reservoir. Fill tank with fluid
and circulate through system. Total amount of fluid in system is approximately 3 L.

3.14.6 TEST START UP

[Link] Connect instrumentation for measuring torque, pressure, motor-speed, and temperature. Calibrate
transducers and thermocouples. (Note: If compression type load cell is used, calibrate torque with lever-arm
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Ford Motor Company Page 18 of 22 MERCON V Specification
 tare included in calibration.)

[Link] Cycle piston pressure five times from 0 kPa to 310 ± 10 kPa pressure (3 seconds on, then 3 seconds off) to
promote oil saturation throughout the friction material.

[Link] Start recording devices. Check for leaks and check operation of transducers, pump, instrument air, etc

[Link] Test to the following test-cycle sequence in Table VIII:.

TABLE VIII - ANTISHUDDER DURABILITY TEST SEQUENCE

Cycle Cycle Test Bath Temp Apply Speed Constant Slip

Number Type Parameters Temp. Controlled Pressure [kPa] [rpm] Duration Duration
Table Limit [°C] [sec] [sec]

Initial Preheat and Break-In Cycles:

1 Constant 150 max No 0 180 3600 0

2-6 Ramp TABLE IX 118 max No 254.8 220 (peak)

7-11 Dynamic TABLE X 118 max No 254.8 3600

12 Dynamic TABLE XI 118 max No 254.8 3600 (dyn)

& Static 0.7 (stat)

13 Constant 150 max No 254.8 180 600 600

14-18 Ramp TABLE IX 118 max Yes 254.8 220 (peak)

19-23 Dynamic TABLE X 118 max No 254.8 3600

24 Dynamic TABLE XI 118 max No 254.8 3600 (dyn)

& Static 0.7 (stat)

Total of 14 Standard ASD Test Block Cycles (Approxiamately 1050 Cycles):

25 Constant 150 max No 254.8 180 3000 3000

26-45 Dynamic TABLE X 150 max No 254.8 3600

46 Constant 150 max No 254.8 180 3000 3000

47-66 Dynamic TABLE X 150 max No 254.8 3600

67 Constant 150 max No 254.8 180 3000 3000

68-87 Dynamic TABLE X 150 max No 254.8 3600

88 Constant 150 max No 254.8 180 3000 3000

89-93 Ramp TABLE IX 118 max Yes 254.8 220 (peak)

94-98 Dynamic TABLE X 118 max No 254.8 3600

99 Dynamic TABLE XI 118 max No 254.8 3600 (dyn)

& Static 0.7 (stat)

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Ford Motor Company Page 19 of 22 MERCON V Specification
 TABLE IX - Ramp Cycle Sequence

Duration Total Time

Event Operation
(seconds) (seconds)
1 20.0 0.0 - 20.0 LS (Low speed) motor on, force applied, speed increased from 0 to 220 rpm
2 20.0 20.0 - 40.0 LS motor on, force applied, speed decreased from 220 to 0 rpm*

* mu calculated during deceleration at 1.20 and 0.35 m/sec sliding speed

TABLE X - Dynamic Cycle Sequence

Duration Total Time

Event Operation
(seconds) (seconds)
1 13.0 0.0 - 13.0 HS (High Speed) motor on, force released
2 0.1 13.0 - 13.1 HS motor off, force released

3 3.0 13.1 - 16.1 HS motor off, force applied

4 1.9 16.1 - 18.0 HS motor off, force applied (soak)

5 2.0 18.0 - 20.0 HS motor off, force released (dwell)

TABLE XI - Dynamic & Static Cycle Sequence

Duration Total Time

Event Operation
(seconds) (seconds)
1 13.0 0.0 - 13.0 HS (High Speed) motor on, force released
2 0.1 13.0 - 13.1 HS motor off, force released
3 3.0 13.1 - 16.1 HS motor off, force applied
4 1.9 16.1 - 18.0 HS motor off, force applied (soak)
5 0.5 18.0 - 18.5 HS motor off, force released (dwell)
6 1.0 18.5 - 19.5 SD (Static motor) on to engage static drive
7 1.0 19.5 -20.5 SD motor off, force released

8 1.0 20.5 - 21.5 SD motor off, force applied

9 3.9 21.5 - 25.4 SD motor on, force applied

10 2.0 25.4 -27.4 SD motor off, force released

Note for Table VIII: Standard ASD Test Block is repeated for cycles 100-174, 175-249, etc. One ASD Test Block
represents approximately 4 hours of testing.

For Cycles in which Temp Hold = "Y“, the bath temperature must equal the set point prior to proceeding. Due to the
lack of heat contribution (clutch is not slipping), the bath temperature set point will not be achieved for Cycle 1.

3.14.7 REQUIRED RECORDINGS

[Link] Record plate interface temperatures, bulk oil temperature (in test head), bath temperatures, torque, apply
pressure, and motor speed.

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Ford Motor Company Page 20 of 22 MERCON V Specification
 [Link] Equation for calculating coefficients of friction using torques from test machine:

dµ/dV CALCULATION
In each group of five ramp cycles, data from the deceleration ramps of the last three (of five) cycles are
used for dµ/dV calculation. Using at least ten data points for each parameter, calculate average values of
slip speed, torque, and apply pressure at both slip speed targets. The high slip speed target is 1.20
meters/second. The low slip speed target is 0.35 meters/second.

The dµ/dV value is calculated from the above averages. µ is calculated according to the following equation
and constants:
T T = Torque (Nm)
µ = P = Pressure (kPa)
PARN A = Apply Piston Area (m²)
R = Mean Friction Radius (m)
N = Active Friction Surfaces
Apply Piston Area should be 0.015 m²
Mean Friction Radius = 0.059 m
Active Friction Surfaces = 2

dµ/dV is calculated at follows:

µ (1.20) – µ (0.35) µ = friction coefficient
---------------------------- X 1000 V = sliding speed
V(1.20) – V(0.35) µ (1.20) = µ calculated at 1.20 m/s target speed
µ (0.35) = µ calculated at 0.35 m/s target speed
V(1.20) = V calculated at 1.20 m/s target speed
V(0.35) = V calculated at 1.20 m/s target speed
3.14.8 TEST RESULTS REQUIRED FOR REVIEW
[Link] Plot of dµ/dV vs. time

[Link] Data Report Table on Form 10.

3.14.9 REFERENCE RUNS

th
Perform a reference run after every 8 candidate with RDL3208E and Shell M1375.3 as the reference fluids with
Dynax D-531-70H friction material.

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Ford Motor Company Page 21 of 22 MERCON V Specification
 3.15 CYCLING TEST

FOR TEST PROCEDURE 3.15, ATTACH GM APPROVAL LETTER (IF APPLICABLE) AND ALL DATA
INCLUDING CHARTS, GRAPHS AND TORQUE TRACES.

3.15.1 Perform the cycling test as defined in the test procedure outlined in the General Motors Automatic Transmission Fluid
®
Qualification Program and Procedures DEXRON III H – Revision June 2003. Requirements are as outlined in that
specification. These requirements pertain to both test procedure and reporting.
®
3.15.2 The cycling test requirement is waived for fluids presently approved to the DEXRON III specification provided the
®
sample submitted for approval to MERCON meets all of the following criteria and is submitted to the independent
laboratories in the following manner:

A. A signed affidavit accompanies the submission stating that the fluid is identical in formulation to that which
®
received the DEXRON III approval.
®
B. The fluid submitted and mentioned above is in a container identified with the DEXRON III number it received
from General Motors when the fluid was approved.

C. A copy of the cycling test report, which confirms passage of the test and was used by GM to grant the
®
DEXRON III license, is submitted to the Ford Service Automatic Transmission Fluid Committee.

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Ford Motor Company Page 22 of 22 MERCON V Specification