| 6R | |
|---|---|
| | |
| Overview | |
| Manufacturer | Ford Motor Company |
| Production | 2005–present |
| Model years | 2005–present |
| Body and chassis | |
| Class | 6-speed longitudinal automatic transmission |
| Related | GM 6L ZF 6HP Aisin AWTF-80 SC |
| Chronology | |
| Predecessor | 5R 44-E · 5R 55-E/N/S/W Ford AOD |
| Successor | Ford 10R 60 · 10R 80 · 10R 140 |
The 6R is a 6-speed automatic transmission for longitudinal engine placement in rear-wheel drive vehicles. It is based on the ZF 6HP26 transmission [1] and has been built under license by the Ford Motor Company at its Livonia Transmission plant in Livonia, Michigan. The 6R debuted in 2005 for the 2006 model year Ford Explorer and Mercury Mountaineer.
It uses a Lepelletier gear mechanism, [2] an epicyclic/planetary gearset, which can provide more gear ratios with significantly fewer components. This means the 6R is actually lighter than its five-speed 5R 44-E and 5R 55-E predecessors.
The 6R 80 was available in 2009–2017 Ford F-150 trucks (and 2018–2020 only paired with the 3.3L V6 engine). It features an integrated "Tow/Haul" mode for enhanced engine braking and towing performance. For the 2011 model year, the transmission was revised to provide smoother shifts, improved fuel economy, and overall better shift performance. Most notable of the improvements was the addition of a one-way clutch that provided smoother 1–2 up-shifts and 2–1 down-shifts. The transmission has a relatively low 1st gear and two overdrive gears, the highest of which is 0.69:1. This provides exceptional towing performance when needed, while maximizing fuel economy by offering low engine speeds while cruising.
The 6R 80 can be found behind the 3.7L V6 all the way up to the 6.2L V8. Ford has stated that while the transmission is used in multiple applications, each transmission is optimized and integrated differently depending on the engine it is mated to. The 6R 80 features "Filled for Life" low viscosity synthetic transmission fluid (MERCON LV), though a fluid flush is recommended at 150,000 mi (241,000 km ) if your truck falls under the classification of "Severe Duty" operation. The transmission, as used in the Ford F-150, has a fluid capacity of 13.1 US qt (12.4 L ) and weighs 215 lb (98 kg ).
| Model | First Delivery | Gear | Total Span | Span Center | Avg. Step | Compo- nents | ||||||
|---|---|---|---|---|---|---|---|---|---|---|---|---|
| R | 1 | 2 | 3 | 4 | 5 | 6 | ||||||
| Ford 6R 60 · 6R 80 | 2005 | −3.403 | 4.171 | 2.340 | 1.521 | 1.143 | 0.867 | 0.691 | 6.035 | 1.698 | 1.433 | 3 Gearsets 2 Brakes 3 Clutches |
| Ford 6R 140 | 2005 | −3.128 | 3.974 | 2.318 | 1.516 | 1.149 | 0.858 | 0.674 | 5.899 | 1.636 | 1.426 | |
| ZF 6HP All | 2000 [b] | −3.403 | 4.171 | 2.340 | 1.521 | 1.143 | 0.867 | 0.691 | 6.035 | 1.698 | 1.433 | |
The main objective in replacing the predecessor model was to improve vehicle fuel economy with extra speeds and a wider gear span to allow the engine speed level to be lowered (downspeeding). The layout brings the ability to shift in a non-sequential manner – going from gear 6 to gear 2 in extreme situations simply by changing one shift element (actuating clutch E and releasing brake A).
In order to increase the number of ratios, ZF has abandoned the conventional design method of limiting themselves to pure in-line epicyclic gearing and extended it to a combination with parallel epicyclic gearing. This was only possible thanks to computer-aided design and has resulted in a globally patent for this gearset concept. The 6R is based on the 6HP from ZF, which was the first transmission designed according to this new paradigm. After gaining additional gear ratios only with additional components, this time the number of components has to decrease while the number of ratios still increase. The progress is reflected in a much better ratio of the number of gears to the number of components used compared to existing layouts.
| With Assessment | Output: Gear Ratios | Innovation Elasticity [b] Δ Output : Δ Input | Input: Main Components | |||
|---|---|---|---|---|---|---|
| Total | Gearsets | Brakes | Clutches | |||
| 6R Ref. Object | Topic [b] | |||||
| Δ Number | ||||||
| Relative Δ | Δ Output | · | Δ Input | |||
| 6R 5R 44-E/55-E [c] | 6 [d] 5 [d] | Progress [b] | 8 9 | 3 [e] 3 | 2 3 | 3 3 |
| Δ Number | 1 | -1 | 0 | -1 | 0 | |
| Relative Δ | 0.200 | −1.800 [b] · | −0.111 | 0.000 | −0.333 | 0.000 |
| 6R 3-Speed [f] | 6 [d] 3 [d] | Market Position [b] | 8 7 | 3 [e] 2 | 2 3 | 3 2 |
| Δ Number | 3 | 1 | 1 | -1 | 1 | |
| Relative Δ | 1.000 | 7.000 [b] · | 0.143 | 0.500 | −0.333 | 0.500 |
| ||||||
| Car Type | Ratio |
|---|---|
| 4.10 | |
| 3.73 | |
| 3.55 | |
| 3.31 | |
| 3.15 | |
| 2.73 |
The ratios of the 6 gears are nicely evenly distributed in all versions. Exceptions are the large step from 1st to 2nd gear and the almost geometric steps from 3rd to 4th to 5th gear. They cannot be eliminated without affecting all other gears. As the large step is shifted due to the large span to a lower speed range than with conventional gearboxes, it is less significant. As the gear steps are smaller overall due to the additional gear(s), the geometric gear steps are still smaller than the corresponding gear steps of conventional gearboxes. Overall, therefore, the weaknesses are not overly significant. As the selected gearset concept saves up to 2 components compared to 5-speed transmissions, the advantages clearly outweigh the disadvantages.
It has a torque converter lock-up for all 6 forward gears, which can be fully disengage when stationary, largely closing the fuel efficiency gap between vehicles with automatic and manual transmissions.
In a Lepelletier gearset, [2] a conventional planetary gearset and a composite Ravigneaux gearset are combined to reduce both the size and weight as well as the manufacturing costs. Like all transmissions realized with Lepelletier transmissions, the 6HP also dispenses with the use of the direct gear ratio and is thus one of the very few automatic transmission concepts without such a ratio.
| In-Depth Analysis With Assessment [a] [b] [c] | Planetary Gearset: Teeth [d] Lepelletier Gear Mechanism | Count | Total [e] Center [f] | Avg. [g] | |||
|---|---|---|---|---|---|---|---|
| Simple | Ravigneaux | ||||||
| Mfr. Model | Version First Delivery | S1 [h] R1 [i] | S2 [j] R2 [k] | S3 [l] R3 [m] | Brakes Clutches | Ratio Span | Gear Step [n] |
| Gear Ratio | R | 1 | 2 | 3 | 4 | 5 | 6 |
| Step [n] | [o] | [p] | |||||
| Δ Step [q] [r] | |||||||
| Shaft Speed | |||||||
| Δ Shaft Speed [s] | |||||||
| Specific Torque [t] | [u] | [u] | [u] | [u] | [u] | [u] | [u] |
| Efficiency [t] | |||||||
| Ford 6R 60 6R 80 | 600 N⋅m (443 lb⋅ft ) 800 N⋅m (590 lb⋅ft ) 2005 (both) | 37 71 | 31 38 | 38 85 | 2 3 | 6.0354 1.6977 | 1.4327 [n] |
| Gear Ratio | −3.4025 [o] | 4.1708 | 2.3397 [p] | 1.5211 | 1.1428 [r] [s] | 0.8672 | 0.6911 |
| Step | 0.8158 [o] | 1.0000 | 1.7826 [p] | 1.5382 | 1.3311 | 1.3178 | 1.2549 |
| Δ Step [q] | 1.1589 | 1.1559 | 1.0101 [r] | 1.0502 | |||
| Speed | -1.2258 | 1.0000 | 1.7826 | 2.7419 | 3.6497 | 4.8096 | 6.0354 |
| Δ Speed | 1.2258 | 1.0000 | 0.7826 | 0.9593 | 0.9078 [s] | 1.1599 | 1.2258 |
| Specific Torque [t] | –3.3116 –3.2665 | 4.0186 3.9436 | 2.2837 2.2559 | 1.5107 1.5055 | 1.1359 1.1325 | 0.8633 0.8613 | 0.6867 0.6845 |
| Efficiency [t] | 0.9733 0.9600 | 0.9635 0.9455 | 0.9761 0.9642 | 0.9931 0.9897 | 0.9939 0.9910 | 0.9955 0.9932 | 0.9937 0.9905 |
| Ford 6R 140 | 1,400 N⋅m (1,033 lb⋅ft ) 2005 | 49 95 | 37 47 | 47 97 | 2 3 | 5.8993 1.6361 | 1.4261 [n] |
| Gear Ratio | −3.1283 [o] | 3.9738 | 2.3181 [p] [r] | 1.5158 | 1.1492 [r] [s] | 0.8585 | 0.6736 |
| Step | 0.7872 [o] | 1.0000 | 1.7143 [p] | 1.5293 | 1.3190 | 1.3389 | 1.2744 |
| Δ Step [q] | 1.1210 [r] | 1.1594 | 0.9854 [r] | 1.0504 | |||
| Speed | -1.2703 | 1.0000 | 1.7143 | 2.6216 | 3.4580 | 4.6290 | 5.8993 |
| Δ Speed | 1.2703 | 1.0000 | 0.7143 | 0.9073 | 0.8364 [s] | 1.1710 | 1.2703 |
| Specific Torque [t] | –3.0449 –3.0035 | 3.8290 3.7576 | 2.2615 2.2333 | 1.5055 1.5003 | 1.1419 1.1383 | 0.8543 0.8522 | 0.6692 0.6669 |
| Efficiency [t] | 0.9733 0.9601 | 0.9635 0.9456 | 0.9756 0.9635 | 0.9932 0.9898 | 0.9937 0.9906 | 0.9952 0.9927 | 0.9934 0.9900 |
| ZF 6HP | All [c] · 2000 [v] | 37 71 | 31 38 | 38 85 | 2 3 | 6.0354 1.6977 | 1.4327 [n] |
| Gear Ratio | −3.4025 [o] | 4.1708 | 2.3397 [p] | 1.5211 | 1.1428 [r] [s] | 0.8672 | 0.6911 |
| Actuated Shift Elements | |||||||
| Brake A [w] | ❶ | ❶ | ❶ | ❶ | |||
| Brake B [x] | ❶ | ❶ | ❶ | ||||
| Clutch C [y] | ❶ | ❶ | |||||
| Clutch D [z] | ❶ | ❶ | |||||
| Clutch E [aa] | ❶ | ❶ | ❶ | ||||
| Geometric Ratios | |||||||
| Ratio R & 3 & 6 Ordinary [ab] Elementary Noted [ac] | |||||||
| Ratio 1 & 2 Ordinary [ab] Elementary Noted [ac] | |||||||
| Ratio 4 & 5 Ordinary [ab] Elementary Noted [ac] | |||||||
| Kinetic Ratios | |||||||
| Specific Torque [t] R & 3 & 6 | |||||||
| Specific Torque [t] 1 & 2 | |||||||
| Specific Torque [t] 4 & 5 | |||||||
| |||||||