Raybestos Begins Its 2nd Century of Innovation

by Steve Bodofsky

n 1890, Gottlieb Daimler and Wilhelm Maybach began the first successful auto manufacturing company the Daimler Motor Company. Just 12 years after those first cars rolled out into the consumer market in 1902 the A.H. Raymond Company opened its doors in Bridgeport, Connecticut, manufacturing brake linings and clutch facings. They created the first non-charring, asbestos-andcopper wire brake lining, offered under the trade name Raybestos. It was the first of many innovations that would display the Raybestos name in the next 100+ years. Today, the Raytech Corporation employs about 1,400 people in 8 locations around the world: 6 in the US, one in Germany and one in China. Its among the largest dry and wet clutch manufacturers in the world, and has expanded from clutches and brakes into filters, solenoids and more. Not bad for a tiny, 4-person company that got its start in a little corner of Connecticut just over a hundred years ago.

Over 100 Years of Friction Products

Raybestos was the first independent

manufacturer of automatic transmissions clutches in the world. Raybestos is a friction material manufacturer; thats what we do, says Al Avila, general manager of Raybestos Powertrain. Whether its the friction material on a clutch, torque converter piston, or band, when were talking tribology the study of friction thats Raybestos. We have hundreds of different formulas in Raybestos library of friction material. A tremendous amount of research and development goes into formulating each unique material, depending on the properties required for each individual application. How do the engineers at Raybestos identify the friction requirements for a specific transmission? Chris Horbach, Raybestos Powertrains chief application engineer and tech support supervisor, explains: In todays competitive environment, the process begins with thermoelastic modeling. Usually, we already have the dimensions and piston geometry, as well as other important data. We plug those numbers into our modeling software, which can simulate the vehicle under a variety of different operating conditions. The program indicates areas of high temperature concentration, high stress, and so on,

allowing us to make changes to our friction choices, and even make design change suggestions to the manufacturer to improve clutch performance and durability. Even if they have a good working system, the software allows us to simulate different friction combinations to find something better. Once the simulations are complete, we may use the results to select a new friction material and thickness to create a sample clutch pack for dynamometer testing. By the time we install a clutch pack in vehicles for evaluation, we know we have a winner.

An Aftermarket Supplier
Of course, Raybestos work for the OEMs is only the first step in their ongoing quest for newer, better friction materials. From there, Raybestos engineers use similar evaluation techniques to address clutch performance issues for the aftermarket. How does Raybestos determine friction requirements for transmissions where they dont supply the clutches to the OEMs? In that case, Raybestos reverse-engineers the unit, by analyzing the factory clutches and their operational requirements, such as vehicle weight,

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GEARS May/June 2007

Frank Slocum

Al Avila

Irvin Gers

Nancy Irvin

Kim Stevens

Chris Horback

Group Meeting

applied horsepower, clutch dimensions and so on. Our tech center can analyze the OE materials and determine the composition of the facings, so we can provide a comparable replacement clutch, says Chris. Once we have that, we put it into test vehicles, to make sure it performs as well or better than the OE product.

Tech Advisory Panel

The advisory panel will typically meet for about two days, during which time Raybestos will share the most intimate details of its operations. And the panel will provide feedback on a wide range of issues, even marketing and advertising. The information the advisory panel provides is invaluable to us, says Al. Without them, many of our decisions would be nothing more than a guess.

neers had developed that never made it to the street and asked, Why cant we offer them to the aftermarket? An early example of a product that never made it off the shelf for OE was Raybestos SW Carbon clutch material. According to Raybestos, SW Carbon is the only material available thats comparable to GMs ECCC torque lining. Other manufacturers offer products that are similar in design, but the SW Carbon is the only material that offers comparable performance to the OE material, because its a true carbon material, not a carbon impregnated paper. However, SW Carbon wasnt being offered to OE or the aftermarket. Raybestos found that torque converter rebuilders didnt have a replacement material for the aftermarket, so they provided the SW Carbon clutch solution. With that, Raybestos Solutions was born. Raybestos Solutions set us apart from other clutch manufacturers, explains Al. But more importantly, it provided effective, well-engineered solutions to real problems facing the transmission repair industry. The SW Carbon and the Z Pak are good examples of this. Of course, everyone knows Raybestos as a clutch manufacturer; 19

How does Raybestos identify the issues that are important to the industry? They go right to the source: the technicians in the field. Weve met with technicians for years, to keep on top of the problems they face, explains Frank Slocum, vice president of sales and marketing for Raybestos Powertrain. About six years ago we formed a technical advisory panel, including shop owners and technicians from all across the country who have a sincere interest in improving the Raybestos line. We meet once or twice a year, and discuss the trends and conditions they find important. The panel was created for one purpose, agrees Al. To provide us with feedback on our products, from people who know this business. Sometimes that feedback is positive; other times its not. Sometimes their feedback is totally different than we expected. GEARS May/June 2007

Raybestos Solutions

The concept of Raybestos Solutions has been simple: To identify problems in todays transmissions, and find solutions to correct them. In some cases, the solution might be simply to replace the clutch lining with something more durable. In others, it requires completely redesigning the clutch assembly. Raybestos Solutions was the brainchild of Al Avila, who came from the repair side of the industry. As I began to get involved with the process for creating an OE product, I learned that many things impact the selection process. The clutch that gets approved isnt always the best one for the application. So I thought: What if we could focus on the best clutch for that application? It would be a great opportunity to provide a real solution for shops. I started looking at all the solutions our engi-

Raybestos Begins Its 2nd Century of Innovation however, Raybestos Solutions goes beyond clutches, including products such as a Chrysler speed sensor, which corrects repeat failures that are common with the OE sensors. Theyre currently working on a new pressure control solenoid, designed to offer smoother, more precise control of system pressures. People ask us, Why are you making these components? Theyre not clutches, and the answer is simple: They need to be made. Its a problem that needs a solution. Thats what Raybestos Solutions is all about, said Frank. meaning only the steel plates carry away heat. In a single-sided clutch, every plate has a steel side to help transfer heat away from the clutch. The added heat capacity greatly improves clutch durability. Single-sided clutches have a downside: Because of their heat transfer abilities, one side of the clutch will be cooler than the other. This can cause the clutch to distort or cup. That in itself isnt a problem; what is a problem is that the amount of cupping varies, depending on the clutchs position in the clutch pack. This variation reduces contact area, which in turn reduces holding capacity and increases stress and heat within the pack. The next objective of the Z Pak was to improve the contact area and increase holding capacity, not by eliminating the cupping, but rather to take advantage of the laws of physics by designing clutches that would all cup at the same rate. This allowed Raybestos engineers to take advantage of the additional heat transfer of the single-sided clutch, while providing the holding capacity necessary to maintain durability. The result is a super clutch, with superior heat transfer, increased holding capacity and enhanced durability. What makes the Z Pak unique isnt that its a great clutch, explains Al. The industry expects great clutches from Raybestos. What makes the Z Pak unique is that weve gone a step further, creating a completely new design to replace the OE clutch, making it better than the original. So many technicians were having trouble with the 4L60/4L60E 3rd clutch, says Frank. Theyd take it apart, put it back together in factory condition and send it down the road, only to have it come back again and again. Raybestos examined and analyzed the assembly, and designed a Z Pak kit to address its inherent problems. We have all sorts of testimonials telling us how successfully we solved the problems, says Frank. When we ask about their comeback rates with the Z Pak installed, they laugh and say I dont have them anymore!

Racing Clutches vs High Performance

The Z Pak - Its Revolutionary

The Z Pak could probably be considered the flagship product of Raybestos Solutions. A revolutionary clutch replacement kit, designed by Dr. Przemyslaw Zagrodzki, also known as Dr. Z from whom it takes its name the Z Pak improves heat dissipation, holding capacity and durability. Every transmission professional knows that heat is one of the biggest dangers to the automatic transmission. There are only two ways to dissipate heat from a clutch: through the oil or the steel plates. On a two-sided friction plate, the friction material actually insulates against heat transfer to the clutch core,

The Blue P l a t e Special was introduced in 1985, primarily for drag racing. More recently, the Blue Plate Special evolved into the gen2 Blue Plate Special, which is better suited for all types of racing. What many people dont realize is that, while the Blue Plate Special is unparalleled in its performance on the track, it really isnt a heavy-duty clutch. In fact, if used on the road, Blue Plate performance is likely to be disappointing not because it isnt a great clutch, but because it was never designed for that type of use. Thats why Raybestos designed the Stage-1 clutch. Stage-1 is a dropin replacement that provides a greater coefficient of friction and increased long-term durability. Its a robust, high performance clutch designed to work under high torque conditions. The Blue Plates are designed for high speed, high energy use. Think of it like a thoroughbred, explains Frank. Hes bred to run, not pull a wagon. Its an entirely different set of demands. If you tow your car to the track on a trailer, Blue Plates are the racing clutch youre looking for. If you drive it to the track, you want Stage-1s. Theres a huge sector of the motoring public that wants to put larger tires on their cars, install a more radical camshaft or turbocharge it maybe just up the compression or install headers. Theyre running 5% 10% maybe even 25% more power. They need something to handle that extra power and still be street ready. Thats what GEARS May/June 2007

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the Stage-1 was designed for. When thinking Blue Plates, think ENERGY!

But it really doesnt matter whether its a Made in America-pride issue or quality-pride issue; either way, you win, because the folks at Raybestos take great pride in the quality of their American-designed and built products.

Got a Problem? Call Raybestos!

T h e m o r e energy or horsepower the better Blue Plates perform. Theyre for the serious racer.

Raybestos and ATRA: A Winning Combination

Made in the USA

There can be little doubt that we operate in a global economy, and Raybestos is no exception. They have factories in Germany and China, as well as those in the United States, and theyre constantly looking for new markets all around the world. However, most of the production from those factories provide product for the countries where theyre located. Nearly all of the parts Raybestos sells in America are made right here in the USA. Were very proud that Raybestos products are primarily made in the US, says Al. Our electrical components, wet friction products, and steel plates are manufactured here. We have strategic partners who manufacture their products here, as well. We display Made in the USA proudly, because we want our customers to know that Raybestos is committed to manufacturing here, and employing US workers. We consider the US aftermarket to be our primary market; even though our international market continues to grow, were proud to call ourselves Made in the USA. Its not just an American-pride issue, although theres no doubt its a powerful motivation. Its about product consistency; good enough just isnt good enough for Raybestos. And the only way theyve been able to assure consistent quality in their products has been to control their manufacturing. That means keeping the business right here in the US, where they can monitor every step in the process. GEARS May/June 2007

Raybestos has been a visible supporter of ATRA for years. The Raybestos Kickoff Luncheon at ATRAs annual expo has become a staple since its inception, over 14 years ago. They make a point of setting up displays at a number of ATRA seminars every year. Were strong supporters of the independent rebuilder, says Frank. We see ATRA as a valuable connection with the independent transmission shop. By supporting ATRA, we can do our part to help support this industry. It gives us a way of showing our appreciation to our customers. The folks at Raybestos are quick to acknowledge the importance of the training and information that ATRA provides. In fact, theyre troubled by how few technicians take advantage of it: Less than 10% of the working technicians attend this training, says Frank. That has us concerned, because we believe the only way to remain profitable in todays market is through continued education. Were constantly exploring ideas to attract new technicians to these classes, he said. We believe thats a critical step in keeping our industry strong.

If you have a problem with any Raybestos parts, they want to hear from you. You can call them, toll-free, at 1-800-729-7763. During regular business hours, M-F 8AM - 5PM EST. This number doesnt ring through to a voicemail system or answering machine; the phone is answered by a real person, wholl forward you to the right person to address your specific concerns. If theres a problem with one of our products, we want to know about it so we can correct it, explains Chris. Whether its a product concern, or an idea to improve a design, we want to hear from you. Al was quick to agree: The relationship we have with our customers is one of our most valuable assets. It allows us to be more responsive to their concerns. We like to think were more approachable than most manufacturers. We have a tremendous respect for the people in this industry, and are happy to work with them and take care of any problems, whatever they may be. For over 100 years, Raybestos has been at the forefront of clutch and brake technology. Its been a long and sometimes bumpy road to get where they are today. After a hundred years on the road, some might be content to sit back and enjoy the ride. Not Raybestos: Theyre driving with a purpose one thats sure to lead the field as they begin their second century of innovation.

Raybestos Lab

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