DRIVE LINE News and Updates From Jasper Engines & Transmissions December 2007 In This Issue... JASPER Opens European Front with Customer Profile: Remanufactured VW Engine Smutny & Ross Auto Repair pg. 2 Jasper Engines & Transmissions has parts. By providing parts such as valve issued its first European engine… the covers, oil pans and oil filter adapters Volkswagen 1.8L DOHC five-valve we can be sure the engine is completely Chuck Lynch: Machining The engine. This engine fits the 1997- 2006 clean. JASPER utilizes a process where Cadillac 4.6L Volkswagen Beetle, Golf, GTI, Jetta and the baffle plate is removed from the Northstar Block pg. 3 Passat, and 1997-2006 Audi A4 and TT. valve cover and reinstalled after clean- JASPER’s remanufactured ing to eliminate all of the hidden Volkswagen engines are supplied with contamination.” AAM Introduces valve covers and oil pans. Late-model Cylinder head machining for the Gear Set for applications come with oil filter Volkswagen 1.8L can be difficult with Fuel Economy pg. 4 adapters. This makes for more stock standard equipment due to the small numbers due to different variations, but diameter heads and guides. JASPER We Have Our JASPER takes these steps to ensure uses a single-point CNC cutting tool to Calendar Winners there is no contamination in this engine. ensure the proper seal. for 2008! pg. 5 “We have found that oil sludge and All JASPER remanufactured caking is a common problem with these Volkswagen engines are provided with engines,” says Justin Zipp, JASPER’s OEM gaskets, bearings, timing compo- Import Quality Control Engineer. “This nents and oil pumps. Variable cam tim- buildup can be found in all of these ing versions of the engine receive new OEM actuator assemblies. Late model, water pump type blocks receive an updated water pump with a cast impeller rather than plastic. “We found that plastic impellers separate from the shaft,” says Zipp. “The updated water pump prevents early failure.” All JASPER Volkswagen engines are live run tested where they are checked for overall engine operation. Readings for oil pressure, temperature, vacuum and compression are recorded. Every joint and seal is checked to make sure there are no leaks. Published by: The JASPER remanufactured Jasper Engines & Volkswagen 1.8L engine is covered by a Transmissions three-year 100,000 mile nationwide P.O. Box 650 warranty. For more information on this Jasper, IN 47547-0650 Phone: 1-800-827-7455 JASPER’s initial offering in European engines engine, contact JASPER at 1-800-827- Fax: 1-812-634-1820 is the Volkswagen 1.8L DOHC five-valve 7455, or log onto: www.jasperengines.com. www.jasperengines.com engine. Smutny & Ross Auto Repair Profile Located at the corner of Banyan and Walker Streets in South Miami-Dade County, Florida, Smutny & Ross Auto Repair is a family-owned business that takes care of their customers with full service general auto repair. The business started in 1976 as a single bay shop with one mechanic owned by Steve Smutny, Sr. Mean- while, Steven Smutny, Jr. was a college graduate from Temple University. He wanted to be more involved in the fami- ly business and moved back with his father in South Miami. Then there’s the younger son, Bill Smutny. He complet- Air Conditioning. Each Smutny & Ross technician must attend a minimum of 16 continuous education seminars annually in various aspects of automo- tive repair. The company chips in for 1/2 of a technician’s schooling at each seminar. When it comes to using JASPER remanufactured products, Smutny & Ross Auto Repair has been a customer since 2002. Why do they purchase JASPER gas and diesel engines, trans- missions and differentials? “Because it is a superior product with excellent cus- tomer service,” says Steve Smutny, Sr. ed two years of college, then decided to “JASPER has the same values as the help his father and brother run the busi- ones we employ in our shop.” ness and follow in both their footsteps. Customer service is of great impor- Together, Steve Sr. and his sons operate tance at Smutny & Ross. “I have the Smutny and Ross Auto Repair in upmost respect for my customers and I Perrine, Florida. The ‘Ross’ in the com- see them as part of the family,” added pany name represents a previous co- Steve, Sr. It’s part of the reason why owner no longer in the business. the company has tripled in size over the The 5,000 square foot facility, locat- years. As part of their exclusive cus- ed at 9970 Banyan Street, boasts nine tomer service, Smutny & Ross provides service bays and nine total employees. a shuttle service for all their customers. Smutny & Ross is capable of general And when the repairs are of a signifi- Customer vehicle repair, with room to service RV’s cant amount, customers are offered a and trailers for boats and trucks. They free car wash. “Treat the customer the can also handle diesel engine repairs, way you want to be treated,” added electrical service, front end alignments, Steve, Sr. “And fix it right the first tire sales and repairs, and air condition- time.” ing service. As for the future, Smutny & Ross When it comes to experience, plans to be better equipped to handle Smutny & Ross has two ASE Certified the new technology of today’s automo- Master Technicians and four other tech- biles, and continue providing excellent nicians with ASE Certification that range customer satisfaction. from Transmission and Differential to Smutny & Ross Auto Repair in Perrine, Florida, is a family-oriented business with an emphasis on customer satisfaction. 2 Machining The Cadillac 4.6L Northstar Block by Chuck Lynch, JASPER Research & Development Chuck Lynch has been asso- ciated with JASPER since 1994. Lynch has been a member of the Research & Development Department for the past ten years, and has been involved with Associate training in the Gas and Diesel departments. He has earned ASE Certification as an Auto and Truck Technician and a Master Machinist in Gas and Diesel Engines. As the sales popularity of the Cadillac 4.6L Northstar engine has The CNC-controlled boring machine conducts the 20 head bolt hole repairs and 20 main bolt hole repairs on the Cadillac 4.6L Northstar aluminum block. grown for Jasper Engines & Transmis- sions, it has made us take a hard look at 3. Each hole had a steel thread Quality and Accuracy: the methods that we use for processing repair installed with an anaerobic The fourth axis machine allows the cylinder block. sealant. This required removal of the JASPER to ensure that all threaded locating jig. holes are located to print specification The block has thread repair needs that for depth, size and location more accu- are not typical of most cylinder blocks. 4. Once each repair was in the block, rately than jigs can. CNC machining Every head bolt and main bolt hole must specialized broaching tools were used centers rely solely on datum points to have a thread repair installed as the orig- to swedge the thread repairs into the function. Therefore, with cooperation inal threads either fail, resulting in castings and ensure proper thread from gasket suppliers and their part engine failure, or the threads are pulled pitch and diameter. print dimensions we can not only ensure from the casting during the disassembly After reviewing the labor, tooling that all threaded holes are properly process. This condition means that we cost and cycle times, JASPER decided located but we can also ensure that must install 20 head bolt hole repairs and that we must work smarter and try to cylinder bores are going to be properly 20 main bolt hole repairs per block employ less physical means to install located in the gasket combustion open- 100% of the time. the needed thread repairs. Adding a ing. This is true of dimensions such as The method to install these repairs machine to the process was definitely crank to cam bores as well. consisted of different drilling jigs to they way to go, but what type of Tool expense and life: ensure that the thread repairs were machine was the question. Do you just The machining center can increase installed to the proper depth and loca- employ more jigs and fixtures and use a tool life because the proper speed and tions. More of an issue than getting the drill press or boring machine? As we feed ratios are employed for given tool repairs in the correct locations and prop- reviewed the possible other steps that materials and casting materials. Tools er depth was the manpower required. we could incorporate into the process are stored in an automatic changing Each hole had to go through a four-step we decided to proceed with a fourth device, not pitched in a toolbox, there- process to ensure that a quality threaded axis machining center. This would not fore reducing opportunity to damage hole is made for the fasteners. only allow us to drill and tap bolt holes costly tools. Tools are constantly hav- but we could bore cylinders and mill the 1. Each hole was ‘drill reamed’, with ing coolant applied during the machin- gasket surfaces as well. The benefits a specialized type of drill. ing cycle; whereas, when doing process- can be weighed out in three primary 2. Each hole was tapped, which required es by hand it would be a little shot of categories and they are as follows. the removal of drill bushings and lubricant and go to work. replacing them with tapping bushings. (continued on page 6) 3 AAM Introduces Gear Set for Fuel Economy American Axle & Manufacturing turers’ stringent standards. Coordinate (AAM), has made available a new exclu- Measuring Machines (CMM) are then sive aftermarket 3.42 PowerDense® gear used to inspect the parts for accuracy. set for 2003 to 2007 Dodge Ram Heavy Duty 2500/3500 turbo diesel pickups. AAM – Tough to Beat The gear set and its technology was AAM engineering teams have recently showcased at the Automotive advanced the design and manufacturing Aftermarket Products Expo. processes of driveline systems, chassis AAM Aftermarket now offers Dodge systems and metal formed products Ram diesel pickup owners the 3.42 ratio since 1994. AAM designs, tests and gear set as an alternative to the numeri- validates its ring and pinion sets to cally higher ratio gear sets that are cur- vehicle manufacturers’ exact specifica- rently available. The lower ratio set tions. AAM’s on-going programs in reduces engine rpm, which helps NVH, thermal management, vehicle- improve fuel economy under normal system efficiency, dynamics and vehi- driving conditions which exclude haul- cle handling and other disciplines ing, climbing grades, or pulling a trailer. The AAM 3.42 PowerDense gear set is assure customers that the parts they are The 3.42 ring and pinion is designed available for 2003-2007 Dodge Ram Heavy getting incorporate the latest product, to fit inside the original equipment AAM Duty 2500/3500 turbo diesel pickups. process and systems technology. 9.25-inch front and 11.5-inch rear axles without modifications to the transmis- specifications between the gear and the For more information on AAM gear sion or the truck’s on-board computer. In pinion. Backlash is defined as the sets and other products and services, pre-2007 pickups the front axle requires amount of free play between two gears visit the Internet at www.aam.com or a new redesigned differential case along in their operating positions. The results dial 1-800-299-AXLE. with new side and differential pinion are reduced heat, NVH, driveline clunk gears. All 2007 models have the advan- and increased gear set durability. tage of coming with a factory installed Finally, two-cut manufacturing is an redesigned differential case, along with environmentally friendly process. side and pinion gears making the instal- Since the components are dry cut, the lation process easier. presence of a coolant medium at the point of engagement of a tool and a AAM PowerDense® Ring and Pinion Gear Sets component is eliminated. Without coolant, no mists or smoke are A Satisfied JASPER AAM utilizes state-of-the-art face produced. Customer! hobbing to generate the gear tooth form Hey Doug, in a two-cut process. This represents Tough Stuff AAM’s latest effort to enhance NVH, AAM PowerDense® gear sets are Hope all is well with you and durability, quality and reliability of its made from high quality Society of yours. Just had one of the best expe- ring-and-pinion gear sets. The key Automotive Engineering (SAE) steel riences with a motor R/R ever. We advantage of a two-cut gear set occurs purchased only from approved AAM did our first JASPER Engine here in when the components are being hobbed and OEM steel suppliers. Special high the shop and I came in to help the or generated. Hobbing creates more sur- core hardenability steel is utilized to tech myself. face area and equal tooth depth. This enhance the design and manufacturing Well once everything was in, we produces lower alternating bending stress process of the gear sets. just primed the oiling system and levels while creating a more even distri- The specified steel also lends itself dropped the distributor in. We lined bution of loading across all of the teeth. to precision shot peening which extends up the timing marks and it flashed The results are reduced levels of NVH the life of AAM PowerDense® gear right up. No valve noise, no and increased durability. sets. In this process, spherical shot is having to remove valve covers to Another key advantage of the two-cut targeted at the root of the gear teeth and adjust valves. It was great!!! process is the use of continuous index- bombards the surface, resulting in com- You guys put out a great quality ing. In the manufacturing process the pressive stresses to combat fatigue product. Thanks. gear teeth are generated simultaneously loading. The compressive stress with uniform tooth spacing and no increases AAM ring and pinion durabil- Andrew doCouto, Manager imperfections. ity and reliability. KalTire #65 Additionally, the two-cut manufactur- AAM parts are also forged, lapped Kamloops, British Columbia ing process permits tighter backlash and heat treated to meet OE manufac- 4 We Have Our Calendar Winners for 2008! There were a lot of great entrants Ed Geerlings submitted this year, but we have our Muskegon, MI winning photographs to grace the 1979 Chevrolet Corvette pages of the 2008 Jasper Engines & Transmissions Calendar. Joe Williams All of the entrants received this Franklin, GA year were judged on adherence to the 1947 Ford Roadster category, equipment appearance and the quality of the photograph or Malka Kornblatt image. Boca Raton, FL Every qualified entrant received a 1967 Pontiac LeMans Convertible hat autographed by Ryan Newman. All entrants whose work appeared in Larry Burnette 1929 Ford Model ‘A’ Replica owned by Larry the calendar received a $100 gift cer- Bradenton, FL Burnette of Bradenton, Florida. tificate which can be used to pur- 1929 Ford Model ‘A’ Replica chase JASPER remanufactured prod- ucts or wearable items, 24 compli- Thomas & Paula Markley mentary calendars and a special Bellevue, WA JASPER Gift Package. 1972 Pontiac Lemans Sport Congratulations to all our Convertible winners! Wayne Huffman Delonzo & Diane Rhyne Woodsfield, OH Indianapolis, IN 1940 Ford Pickup Street Rod 1966 Ford Thunder Hawk Convertible Mustang Bob & Karen Celauro Bensalem, PA 1967 Ford F-100 Pickup owned by Ray & Mary Ray & Mary Swafford 1965 Buick Skylark Swafford of Ringgold, Georgia. Ringgold, GA 1967 Ford F-100 Pickup Kevin Appel Port Jefferson, NY Joseph & Diane Greschuck 1968 Shelby GT500 Mustang Brandon, FL 1966 Chevrolet Corvette Lynn Hoover & Steven Bickell King of Prussia, PA Louis & Francine Martinez 1970 Plymouth Duster Merced, CA 1971 Chevrolet Nova 1970 Plymouth Duster owned by Lynn Hoover & Steven Bickell of King of Prussia, Pennsylvania. 1947 Ford Roadster owned by Joe Williams of Franklin, Georgia. 1979 Chevrolet Corvette owned by Ed Geerlings of Muskegon, Michigan. 5 (continued from page 3) E-Commerce Portal Drawing Ergonomics and cycle time: October and November were the latest months for Cycle times are reduced because there JASPER’s E-Commerce Portal Drawing. That means we are no jigs to install on the casting, the have two more winners! machine changes the tooling for the differ- The winner for October was Babb’s Auto Enterprises of ent processes and the machine’s elbow and Elgin, Illinois. They selected the $400 rebate coupon. shoulder will not get tired after 15 minutes The winner for November was True Automotive Sales & of leaning on a drill. The rotary table can Service of Everett, Pennsylvania. They selected the race move the block from bank to bank at a package option and will join us for the 2008 Brickyard 400. speed of 710 inches per minute without Don’t forget, when you order through JASPER’s fully- changing hands and so on. customized E-Commerce Portal, your business will be Although this is not new technology, it entered into a monthly drawing. Winners have the choice does go against the grain for engine re- of: manufacturers as we traditionally have a boring machine, a milling machine, and • One day of deep-sea fishing on the Gulf of use a lot of jigs and fixtures for processes. Mexico for one person (includes lodging). It does not mean that the other methods • Two race tickets & hospitality at one of the are bad but it is easy to overlook the JASPER NASCAR Incentive Races in 2008 potential that the machining center can (lodging NOT included). bring to our industry if we just keep doing • A $400 rebate coupon to be used towards future what we have for so many years. JASPER purchases. Transportation to and from all activities is the responsibility of the winner. www.jasperengines.com e-mail: email@example.com 815 Wernsing Road · P.O. Box 650 · Jasper, IN 47547-0650 JASPER ENGINE AND TRANSMISSION EXCHANGE Jasper, IN 47546 Permit 249 U.S. Postage Paid Prst. Std.