New Ford 6 speed automatic bumps Escape mileage 4-6 percent
When Ford launched the redesigned Escape and Mariner compact CUVs last year, the bodies and interiors were all new but the powertrains were largely carried over from the first-generation models. For the 2009 model year, that issue has been addressed with thorough upgrades to both four- and six-cylinder engines. We'll talk more about the engine upgrades next week after we drive them. In the meantime we got an early look at the new automatic transmission for the non-hybrid models. The previous four-speed unit is replaced with an all-new six speed unit dubbed the 6F35.
The new transmission is built at Ford's Van Dyke transmission plant in Sterling Heights, MI in addition to the 6F50 that debuted in the Taurus, Edge and other Ford, Mercury and Lincoln vehicles last year. The new unit uses three planetary gear-sets and five clutch packs to provide the six gear ratios. The extra two ratios allow for a wider overall spread compared to the older four speed. Continue reading about the 6F35 after the jump.
The top gear has the same ratio as the old transmission but first gear is lower. Combined with a numerically lower final drive ratio, off the line acceleration capability is retained while the engine speed while cruising is reduced. The increased number of ratios also allow for smaller steps between gears so that the engine doesn't have to rev as high in each gear. This helps to reduce both noise and fuel consumption. Combined with various internal design improvements, the new transmission helps achieve a 4-6 percent improvement in fuel efficiency.
In addition to CUVs, the new transmissions will also be used in two other cars early next year, likely to be the refreshed Fusion and Milan sedans which use the same engines as the Escape. Ford plans to shift almost all of their automatic transmissions to new six speeds over the next few years. By the end of 2009, they intend to build over 1.4 million vehicles with six speed automatics, double the current amount. By 2012, 98 percent of their North American transmissions will be six speeds. The new 6F35 is also referred to as the 6F mid-range and although Ford officials wouldn't comment on future products, queries about a 6F low-range for the Focus and Fiesta were met with a smile.
FORD'S NEW 6-SPEED AUTOMATIC TRANSMISSION OFFERS 4-6 PERCENT FUEL ECONOMY IMPROVEMENT
- The new 6F35 front-wheel-drive transmission is the latest example of Ford's powertrain technology that increases fuel economy and lowers CO2 emissions.
- The new 6-speed debuts in the 2009 Ford Escape and Mercury Mariner sport-utility crossover vehicles.
- Advanced automatic transmissions represent one part of Ford's comprehensive strategy to improve fuel economy and deliver sustainable solutions for customers.
FACT SHEET: VAN DYKE TRANSMISSION PLANT
DEARBORN, May 7, 2008 – Ford Motor Company is fitting the 2009 Ford Escape and Mercury Mariner with the automaker's newest, advanced 6-speed automatic transmission, further demonstrating its commitment to reduce greenhouse gas emissions and improve fuel economy for customers.
The new 6F35 front-wheel-drive transmission offers a 4 to 6 percent improvement in fuel economy versus conventional 4- and 5-speed automatics, in addition to improved acceleration.
"With a greater gear span, the 6F35 allows the engine to operate at more optimum combinations of speed and load to meet certain driving conditions," said Craig Renneker, chief engineer for new automatic transmissions, Ford Powertrain Operations. "The new transmission also enables the engine to run at lower speeds on the highway, which aids fuel economy."
The 6F35 will be mated to a new 2.5L I-4 engine and a power-improved 3.0L V-6 in the 2009 Escape and Mariner. The engine offers horsepower increases of 17hp for the I-4 and by 40hp for the V-6, while also boosting fuel economy by 1 mpg when mated to the new six-speed transmission. The 2009 Mazda Tribute also will feature the 6F35, as will two other vehicles early next year.
The new 6-speed offers numerous technologies and design features that increase durability, performance and quietness. Ford's patented one-way rocker clutches allow for smoother, quieter, more precise shifts. Working like a socket wrench, the rocker clutches spin freely one way, but securely lock in the other direction. As result, gears are engaged and disengaged more quickly.
Other notable features include:
- Chain-driven secondary gearset – Specifically designed with random-size links, the unique chain reduces noise, vibration and harshness when driving the transmission's secondary gearset.
- Unique pump-filter interface – Virtually eliminates pump whine, contributing to projected best-in-class noise, vibration and harshness characteristics.
- Flat-tow capability – Vehicles equipped with the 6F35 can be flat towed (all four wheels on the road) behind other vehicles without damaging the transmission. When flat towed, the transmission is in neutral, but internal parts rotate, causing heat. With the engine turned off during towing, the pump cannot create pressure to move oil around in the transmission and cool parts. To address this, internal baffling was added to the 6F35 to capture and direct oil to key areas.
- Fluid fill for life – A special blend of transmission fluid is maintenance free for the life of the gearbox.
- Transmission System Characterization – A process that utilizes software to ensure proper transmission operation before a vehicle leaves the assembly plant. During final testing, the functioning of several common shift cycles are matched against established parameters. Variability is then corrected by software in the Powertrain Control Module. The process helps deliver a high-quality, correctly operating transmission to customers from the very first day they drive their new vehicle.
Quality Tested for Durability
Ford automatic transmissions are subjected to hundreds of hours of durability, noise, vibration and harshness (NVH) testing. A series of accelerated durability trials equate to 150,000 miles of the most abusive customer usage under extreme conditions.
"One test for the 2009 Escape was to run in fourth gear with maximum trailer load at 100 mph for 15 miles. And that was repeated about 500 times," explained Rich Rej, 6F35 systems engineer, Ford Powertrain Operations. "We determine what the most abusive driver would do to our transmissions and then we do more to it to make sure that we are delivering a high-quality, durable gearbox for our customers."
Ford also utilizes a state-of-the-art Transmission NVH Hemi Anechoic Chamber that allows engineers to develop hardware to meet noise and vibration targets that will result in a quiet, interior cabin, and yield higher customer satisfaction levels for transmission quietness.
The new 6F35 6-speed automatic transmission is assembled at Ford's Van Dyke Transmission Plant, which also produces the 6F50 6-speed automatic in 2008 models of the Ford Taurus, Taurus X, Edge, Mercury Sable, Lincoln MKX and 2009 Ford Flex and Lincoln MKS.
Ford 6F35 front-wheel-drive, 6-speed automatic transmission:
| Assembly: |
Van Dyke Transmission Plant (Sterling Heights, Mich.) |
|
Gears: |
Sharonville Transmission Plant (Sharonville, Ohio) |
|
Products: |
2009 Ford Escape |
[Source: Ford]
Reader Comments (Page 1 of 2)
armmat 3:03AM (5/08/2008)
All this effort for 4-6% increase in fuel economy when all they had to do was to reduce the size of the vehicle and use a smaller engine to get probably a 30-40% increase in fuel economy.
Human stupidity at its best.
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Cervus 3:23AM (5/08/2008)
Armmat:
Spoken like a true armchair quarterback. "All they had to do..." I think developing a new transmission that can be used in more than one model cost them much less than totally redesigning the whole vehicle from the ground up, which would not have resulted in anywhere near 40% increase anyway. Unless they made it the size of a Mini.
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Chris 7:45AM (5/08/2008)
Cervus, an arm chair quarter back usually makes intelligent observations. I haven't seen one from Armat yet. He comes across as the standard impossible to satisfy whiner. His statements about cars and economy are all incredibly ignorant.
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Dave 7:55AM (5/08/2008)
Most very large companys in general have product developement Road Maps. My guess is that the developement and integration of a six speed has probably been on there for a long time. I don't follow Ford very much at all and am suprised that they only have a four speed auto. I think they are behind their compatition in terms of number of gear ratios. Also, I believe there was an article on this site about Audi going to an eight speed.
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Throwback 8:19AM (5/08/2008)
4 speed autos are still very common, especially in small cars. The Honda Fit is the only "B" segment car that has a 5 speed auto for example. All of the Scions, Yaris, Cobalt, Mazda 3 all use 4 speed automatics. Nissan and Chrysler use CVTs in their small cars. I suspect we will see 6 speeds filter down to these small cars fairly quickly.
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Allen 9:03AM (5/08/2008)
@ Dave...
Ford is not behind on gear ratios. They are right with everyone else. And to be fair, they were the first in class to istall their six speed on full size suvs and in the mid-size segment. In some areas, I can understand your point, but the company as a whole really isn't behind at all.
@ Throwback
tell that to my 5AT 2005 Mazda 3 with manumatic control.
@ Armmat
I was going to say something meaningful but never mind. Just never mind...
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Rick 7:41PM (5/08/2008)
4-6% increase per tank, per gallon, per what?
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MarkR 10:12AM (5/08/2008)
I just hope it is a quality transmission, or Ford will lose their a$$. I was talking about this type of move with a good friend of mine that is a certified auto mechanic with over 40 yrs of experience. He said in general 6 spd's have historically had more problems than a simple 4 which is one reason you haven't seen them with wide spread acceptance in the past.
Sounds to me like the cost benefit analysis wasn't there in the past and now they are forced in to a corner because of government regs. Which means a quality auto might suffer.
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s10 10:54AM (5/08/2008)
@MarkR Historically more problems? How many 6 speed Automatics cars were there in History?
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Wise Golden 11:40AM (5/08/2008)
MarkR -- Ford is rated as the highest quality car. It's better than Toyota. The issues at Ford have to do with product apeal, not quality.
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why not the LS2LS7? 11:45AM (5/08/2008)
See, now that's realistic. When that company (ZF?) was pushing their 8-speed a week ago saying it gets 11% better mpg, that was unrealistic.
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MikeW 12:45PM (5/08/2008)
No, Ford is saying what it will return in the entirely unrealistic EPA fuel economy test.
ZF is correct.
So this is Ford's version of GM's 6t45
http://www.ford.com/about-ford/news-announcements/press-releases/press-releases-detail/pr-ford-accelerates-shift-to-28198
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armmat 1:16PM (5/08/2008)
CERVUS:
Really? Armchair quarterback? Yeah I'd agree if it wasn't for the fact that I'm in the industry. Most of the technology is implementable and available today.
And what's so armchair about it? They have no trouble developing a $50K, 5500lb SUV but they can't build a small, efficient car? So let them reduce the size by half...YOU'D STILL HAVE 4 seats...how many people are in your car most of the time?
So what if the cost is initially high...doesn't anyone think of the future? Uhhh...I guess not given that we are up shits creak with your mentality.
Man, you are a bigtime apologist...it's pathetic. Next time you buy groceries that way 15lbs, make sure you understand the boat you drive is 5500lbs...makes sense doesn't it.
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armmat 1:21PM (5/08/2008)
CHRIS:
Really? And your comments are overflowing? Perhaps I sound ignorant to you because you have a hard time understand basic ideas and changes that need to be made.
People like you and CERVUS are truly pathetic apologists for these companies. You honestly don't have a clue as to what technology is out there and can already be implemented if they decided to spend the money to do it.
It's people like yourself who think it's OK to spend a $1 TRILLION dollars on a war but not have decent schools, decent transportation systems, new alternative energy, new roads and infrastructurs, etc...all at a cost that probably would have been half the cost of the Iraq war.
It's pointless arguing with folks like you because basic math is even hard for you to comprehend.
So let's see your incredibly insightful comments about cars and economy since you have all the answers.
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stas peterson 9:37AM (8/24/2008)
Armmat,
So you work in the industry? Let me guess, you are a rag wiper at an automated car wash. Right?
You have zero understanding of economics, product lead-times, or any other technology.
You have proclivity for believing in conspiracies, and phony science peddled by charlatans, and buy into it hook, line, and sinker.
why not the LS2LS7? 5:21PM (5/08/2008)
Sorry MikeW. No. ZF is full of crap. Going from 6 gears to 8 or 7 gears to 8 will not give 11% better fuel economy. I swear, people are completely blind to how geometric series worked.
If going 7 to 8 got 11%, going from 6-7 would get at least as much, 5-6 at least as much.
So that means 4->5 would add 11%, 5->6 would add 11%, 6->7 would add 11%, and 7->8 would add 11%. So going from 4->8 would add 51% better fuel economy. Do you see Lexus 8 speed getting 50% better fuel economy than before? I never saw a Lexus 460 (or 430) that was rated at 16mpg highway.
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stas peterson 2:08PM (5/13/2008)
To see you clowns c omplain at the US automakers is intensely amusing. Ford and GM compete very well in Europe. (Indeed they make their only profits overseas)
They produce the little pregnant roller skates "A" and "B" cars that Europeans are forced to drive. As their incomes are all swallowed up in socialistic taxes on fuel, incomes, sale, and VAT taxes. And don't forget Carbon and center city taxes, the latest dodges for ever more MONEY.
Those cars don't sell in the US except in a fuel price crisis. Even the European makers don't bring them here, either. No one does. Is every automaker in the world stupid, and only YOU have vision?
Armchair QBs could say redesign. Why should they?
They have them designed for Europe and selling there already.
If Americans want them, then Ford and GM could just do the safety certs and emissions mods, and only add a 1000-1500 pounds of safety stuff, and ruin gas mileage, and them bring them into the US. But they know we wouldn't buy them.
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Noz 12:41PM (7/24/2008)
STAS:
I've read some pretty dumb things in my life but none as dumb as yours.
It's idiots like you who think you know it all that is quite amusing. You come in here and proclaim people don't know economics, etc but somehow you do....lol. You are a true armchair internet loser.
I won't argue with you regarding lifestyle differences of Europe and the US because anyone who has half a brain and any sense of social commonality with his/her neighbor and fellow city colleague won't need to be schooled on how much better Europeans live than Americans overall. If you think Americans don't get taxed MORE overall through a multitude of hidden ways, then more power to you...we need suckers like you to continue the manure coming out of corporations and politicians you so seem to adore here in the US.
If you want to judge people's happiness and prosperity based on the size of their cars and their homes, be my guest....you'll be labeled the village idiot only that much longer.
And keep up the apologist view for GM and Ford...they are going to need all the help they can get....
I honestly never thought people were this stupid...but man...you took the cake.
virgil 10:04AM (5/09/2008)
4-6% equates to an extra 1mpg on the escape. Are yo guys so desperate for news that you have to write an entire article on a 1mpg increase for a car that is not exactly "green" to begin with? C'mon, get some real news.
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MikeW 1:28PM (5/09/2008)
Someone probably had a senior moment, or there was something lost in translation. (yes, 100 centiliter instead of 100 milliliter)
page 16
http://www.zf.com/content/media/konzern/produkte/brosch_ren/Pkw-Broschuere_e.pdf
http://www.zf.com/content/media/konzern/aktuelles/presscenter/presse/at_verbrauch_his-e_zf_sm.jpg
So that 11% is with the stop/start system (and probably all city driving)
http://bioage.typepad.com/.shared/image.html?/photos/uncategorized/2007/05/02/8hp_pic2_zf_lg.jpg
In the real world it all depends on programming. If the POS 4 speed auto that I have been stuck with lately would have better programming regarding its torque converter lockup, it would return 5% better mileage. If it had continuous torque converter clutch slip, the mileage could be 10% better.
So if the performance of the 2.5 & 6 speed auto matches the old 3.0 V6 & 4 speed auto, you can purchase that combination and have your overall mileage improve 10%
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