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SPECIAL

Ford Territory

SPECIAL

Ford Territory

World Class Six-Speed Automatic

Staff, Wednesday August 17, 2005.

Page 1 of 1

Ford Australia now has a world class, premium six-speed automatic transmission available in its locally designed and built vehicles. It is a unique transmission courtesy of the hardware changes and software calibrations engineered by our Powertrain team
? Trevor Worthington, Vice President Product Development, Ford Australia

Ford Australia today announced it would introduce a world class ZF six-speed automatic transmission on high-series and performance Falcon and AWD Territory models, when the new BF Falcon and SY Territory go on sale at the end of October.

?As the first Australian-manufactured vehicles with a six-speed automatic transmission, Falcon and Territory remain at the forefront of engineering innovation, delivering best-in-class technology to Australian drivers while maintaining the Ford hallmarks of affordability and durability,? said Ford Australia Vice President Product Development Trevor Worthington.

?However, the introduction of the ZF 6HP26 six-speed automatic is not just a case of taking an off-the-shelf transmission and putting it into Falcon and Territory.

?Just as we did with the Tremec T56 six-speed manual transmission at BA MkII, with its double synchros on all forward gears and unique gear sets for both the XR6 Turbo and XR8, we have designed the transmission parameters within the ZF unit to suit our engines and our vehicles.

?We have worked closely with ZF Getriebe GmbH and our Premier Automotive Group (PAG) partners to integrate the transmission into the Falcon platform. A number of hardware changes have been implemented, while a host of dedicated software calibrations make this a unique six-speed automatic transmission for Australian vehicles operating in Australian conditions.?

ZF 6HP26 six-speed automatic

The six-speed automatic is a compact and lightweight, high efficiency, high torque capacity transmission with a low first gear, higher top gear and smaller, more graduated steps between each gear.

?The low first gear greatly improves launch feel, while the larger and tighter spread of ratios delivers livelier performance, especially at wide open throttle, along with the added benefits of smoother shift quality and reduced fuel consumption.

?Gear shifts between the top few gears are often imperceptible, while the smaller steps between 3rd, 4th, 5th and 6th also ensure less ?busyness? within the transmission as it determines the right gear.

?The end result of the transmission being in the right gear at the right time is both an improvement in vehicle performance and a reduction in fuel consumption.?

Improved transmission cooling capability in the six-speed auto, by virtue of a heat exchanger, ensures rapid warm-up of the transmission fluid and a more stable operating temperature.

As well as contributing to a reduction in fuel consumption, the improved cooling also enables the maximum towing capacity to be utilised without requiring additional transmission coolers.

Gear train

The six-speed automatic transmission is based on the Lepelletier gear set, which is constructed by connecting a planetary gear to a Ravigneaux gear ? a double planetary gear set commonly used in four-speed automatic transmissions.

The sun of the planetary gear is connected to the housing and cannot rotate, while the carrier of the planetary gear is connected by clutches to the large and small sun wheels of the Ravigneaux gear.

The input shaft is always connected to the ring of the planetary gear and can be simultaneously connected to the carrier of the Ravigneaux gear using a separate clutch.

The output, or driven, shaft is connected to the ring of the Ravigneaux gear.

Hardware changes that have been made to the six-speed automatic transmission to suit Falcon and Territory include:

• Unique transmission main case
• Unique torque converter
• New transmission cross member attachment compatible with both ZF six-speed and ION four-speed automatics
• Transfer case compatibility for Territory AWD application
• Unique output/driveshaft flange

Ford has engineered two versions of the six-speed automatic transmission ? a standard version with a torque capacity of 450 Newton metres and a performance version with a torque capacity of 600Nm.

The performance version features upgraded clutches, with extra plates in the clutch packs, to increase the torque capacity for use with higher torque output engines.

Falcon, Fairlane and Territory models using the Barra 190 engine will be fitted with the standard version, while Falcon and Fairlane models using either the Barra 230, Barra 245T or Boss 260 powerplants will be fitted with the higher torque capacity performance version.

Software and calibration

?The ZF transmission is able to tailor its responses to individual driving styles courtesy of a number of software functions and Driver Recognition features, all designed to deliver increased transmission functionality and performance, and a refined shift quality,? Postgate said.

The Sequential Sports Shift feature introduced on BA Falcon continues as a key element of the new six-speed automatic transmission, offering the same style of adaptive and performance automatic modes as well as total manual control through sequential manual shifting.

Torque converter clutch lock-up is available in all six forward gears, not just in the top two overdrive gears.

When towing heavy loads at low speeds, such as in city driving or through hilly terrain, converter clutch lock-up in all gears assists with better transmission cooling and reduced fuel consumption.

Electronic control of all gearshifts in the six-speed automatic transmission is via clutches rather than bands, delivering a more direct and refined shift quality.

The internal Transmission Control Module (TCM), which is mounted on the hydraulic control valve assembly, or mechatronics unit, has been matched to the transmission's valve body.

The TCM and the valve body are an exact matched pair, with the TCM being calibrated to the specific valve body during assembly, which ensures accuracy of operation and a more refined shift quality.

Calibration features of the six-speed automatic transmission include:

• Grade Control Logic (Automatic modes)
  When driving downhill, with sufficient brake pedal pressure, the transmission will downshift to provide increased engine braking.
  
  Introduced with the four-speed automatic on Territory, Grade Control Logic operates in an even more refined and subtle manner with the six-speed automatic transmission, as the gap between the gear ratios is smaller and the execution of gear changes is smoother.
   
• Upshift prevention at zero throttle (Automatic modes)
  When coasting downhill from rest, this feature inhibits upshifts beyond 2nd gear with zero throttle pedal input, to prevent a ?running away? feeling.
  
   
• Emergency downshift (Manual mode)
  When in manual mode, if the throttle pedal is pushed through the detent to activate the kickdown switch, the transmission will downshift to a lower gear (depending on vehicle speed) to provide acceleration in an emergency situation. The transmission will then revert to full manual control, remaining in the kickdown gear and requiring the driver to input for upshift.

Transient rpm limit

The transient rpm limit allows the engine to momentarily exceed the prescribed rev limit during upshifting. This enables wide open throttle upshifting of gears to be scheduled at an engine speed closer to the rev limiter than would otherwise be possible.

The transient rpm feature allows the engine to exceed 6000 rpm ? up to 6250 rpm ? while the transmission is completing the gear change, thereby taking full advantage of the high rpm performance of Barra 190 and 245T engines.

Driver Recognition

A host of advanced features are accessible to the driver as part of the Driver Recognition software with the six-speed automatic transmission.

?Driver Recognition matches transmission performance to the current driving style by considering acceleration and deceleration rates, brake and throttle applications, and cornering speed, to ensure the vehicle is in the right gear at the right time without undesired gear shifts,? Postgate said.

?The transmission ?learns? the driver's style and assigns a theoretical count system to certain driving scenarios to determine the activation point of particular features.?

The count system extends from a ?base? fuel economy bias (0 counts), through stages such as ?sporty? driver (100 counts), up to ?enthusiast? (200 counts).

The transmission software recognises various performance-based actions, such as rapid acceleration / pullaways, enthusiastic cornering, pushing the accelerator pedal through the detent and moving the shift lever into performance mode, and increases the number of counts accordingly.

By moving the shift lever across from adaptive to performance mode, the driver recognition function increases by 100 counts instantly, making the advanced features more accessible. If the transmission had already learnt to 40 counts in adaptive mode, then when the shift lever is pushed across into the performance mode it would become 140 counts.

In performance mode, driver recognition can learn from ?sporty?, representing 100 counts, up to ?enthusiast? (200 counts).

Counts can be gathered quickly as increases occur in blocks, while a more graduated, single point decrease in counts occurs when you return to a less sporty driving style.

Advanced features

Advanced features accessible through the Driver Recognition software include:

• Brake support downshift (Automatic modes)
  Driver Recognition will enable early downshifting during heavy braking, to provide engine braking and to optimise gear selection for tip-in (throttle reapplication) response.
   
• Gear hold around corners (Automatic modes)
  This feature will enable the selected gear to be held when the vehicle is cornering enthusiastically, to avoid an unwanted upshift or downshift through the corner. Cornering is detected by differential wheel speed and the ABS sensors on each wheel.
   
• Gear hold going uphill / downhill (Automatic modes)
  If the throttle pedal is released when travelling up or down hills, upshifts are prevented to reduce shift busyness on grades (on tip-in when going up hill) and to assist with vehicle speed control (reduce the need for repeated brake application).
   
• Gear hold, fast-off throttle (Automatic modes)
  Upshifts are prevented when the throttle position sensor detects the driver has instigated a rapid lift off of the throttle pedal (fast off) and maintains the current gear until the driver tips-in (reapplies throttle pressure). It also helps prevents shift busyness in sporty driving and inhibits the ?running away? feeling when cresting hills.

?The Driver Recognition features allow for a tailored driving experience, where the transmission rewards different styles of driving at both ends of the performance spectrum,? Postgate said.

?A lower point count and more normalised driving style will deliver significant benefits in terms of refinement and fuel economy, while a greater count will reward sporty driving with sharper responses and a more defined sporty feel.?

All the Driver Recognition features are available on all models fitted with the ZF six-speed transmission, although certain features are more accessible on the sports XR models through a more performance-biased calibration.

Enhanced adaptive shift strategy

The refinement of Ford's adaptive shift programming that occurred on BA Falcon has been further enhanced on BF Falcon and SY Territory.

?The sheer capacity of the ZF transmission to allow for the real-time calculation of a variety of parameters has enabled us to further refine the shift strategy, shift schedules and shift pressures to cover the whole gamut of driving scenarios,? Postgate said.

?With corner, grade and load recognition, the transmission is able to adapt its functionality to suit the situation as demanded by the driver.?

Adaptive modes include economy, performance, sports, uphill, downhill and towing.

The transmission software compares wheel speeds to infer lateral acceleration, as well as longitudinal acceleration versus flat-road acceleration to infer uphill/downhill operation. It then uses this information to assist the driver by inhibiting upshifts or enabling earlier downshifts.

When towing, the transmission perceives the load as a hill and employs gear hold logic. At highway speeds, it will cruise in the appropriate gear to account for the load being towed, which could be 4th, 5th or 6th gear, depending on the precise situation.

The result is improved vehicle performance and fuel economy, as well as improved engine and transmission efficiency.

Accelerator pedal detent and kickdown switch

An accelerator pedal detent feature has been introduced on all automatic Falcon and Territory models, which provides physical feedback when accessing the kickdown switch.

When the accelerator pedal is pushed through the pedal detent to the floor, the kick-down switch (which is integrated into the accelerator pedal mechanism) activates the kickdown feature.

Depending on vehicle speed and the current gear, the kickdown switch will trigger a single or double downshift. However, to prevent potential damage to engine or gearbox, no downshift will occur if the engine speed is already too high to permit a lower gear from being selected.

Revised accelerator pedal map

The accelerator pedal map has been revised for more refined foot rotation versus engine throttle-plate calibrations, which has improved driveability and resulted in more linear vehicle performance.

Remote transmission oil cooler

The new remote transmission oil cooler fitted to all automatic I6 Falcon and Territory models is a heat exchanger mounted to the engine block with a three-way coolant thermostat.

It serves the dual function of using engine coolant to provide rapid warm-up of the transmission fluid during start-up, as well as improved cooling of the transmission under high load/high temperature operating conditions.

?The rapid warm-up feature delivers a significant reduction in friction losses within the transmission, contributing around 1.5 per cent to the overall improvement in fuel economy within the BF program,? Postgate said.

?The remote oil cooler also delivers further refinement to shift quality, as well as reduced fuel consumption, due to better control of the operating temperature of the transmission.?

New fine-feel shift lever

A uniquely styled shift lever has been developed for all Falcon, Fairlane and Territory models fitted with the six-speed automatic transmission.

The new, fine-feel shift lever features a steel shaft, leather-look boot, leather inserts around the selector button and LED illumination.

?The steel shaft delivers a more precise, engineered feel to the transmission lever, with the increased rigidity providing clean, crisp shifts when accessing manual gear selection in the Sequential Sports Shift mode,? Postgate said.

?It also improves the balance of the lever when moving between Drive and the sequential manual shifting positions.?

A new leather-look boot replaces the slider used on the four-speed auto, resulting in reduced noise when changing gears as well as improved feel through the shift lever.

LEDs with daytime and night-time illumination of the ?PRND? positions have been integrated with the instrument panel and interior lighting strategies.

The driver's ability to identify shift lever position and gear selection has been improved, even in low lighting conditions or with the headlights off, through the use of LEDs, which are activated as soon as the driver's door is unlocked.

The selector button on the new shift lever must be depressed to move the transmission from Drive to Neutral, which prevents inadvertent selection of Neutral when on the move.

Transmission protection for the Neutral to Drive shift is also a feature of the six-speed automatic, limiting torque on engagement if the driver attempts a shift from Neutral to Drive under throttle.

Model range
The ZF six-speed automatic transmission will be available on high series and performance Falcon variants, as well as all Territory AWD models.

The six-speed automatic will be standard on:

• Fairmont Ghia
• Fairlane Ghia
• Fairlane G8
• LTD
• Territory TX AWD
• Territory TS AWD
• Territory Ghia AWD

It will also be offered as the automatic transmission option on Falcon XR6 Turbo and XR8 sedans and Utes, while it is specified as mandatory fitment with the optional Barra 230 V8 on Falcon XT and Fairmont.

Falcon XR6 sedan is available with a choice of three transmissions: the Tremec T56 six-speed manual (available from January 2006) fitted as standard, with the option of the improved ION four-speed automatic (at no additional cost) or the new ZF six-speed automatic.

For further information, please contact:
Ford Australia Public Affairs
Phone: 03-9359 8491
Fax: 03-9359 8900

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