NOVEMBER 2000

Inside . . .

Customer Profile:Borches Hi-Tech Auto pg. 2

Durability and Bearing Wear:Truth About Durability pg. 3

2001 Calendar Winners pg. 5

On the Technical Side:A Brief Look Into Surface Finishes pg. 6

Published by:Jasper Engines & TransmissionsP.O. Box 650Jasper, IN 47547-0650 Phone: 1-800-827-7455Fax: 1-812-634-1820www.jasperengines.com

News &Updates

Jasper Engines & Transmissionscontinues its westward expansion.JASPER officially opened its newRemanufacturing facility andDistribution Center during a ribbon-cutting ceremony in Bellingham,Washington.

This new facility utilizes 75,000square feet of production and inven-tory space. Bellingham’s 180 asso-ciates are responsible for JASPER’Sline of remanufactured import gaso-line engines.

The ceremony was held in con-junction with the Tenth Anniversaryof Yamato Engine Specialists Ltd.In 1999, Yamato entered into aStrategic Partnership Agreement tosupply JASPER with their entireimport product line. BellinghamGeneral Manager Asiff Dhananisays the relationship with JASPERhas been a perfect fit. “We have

been able to grow in our productquality and dedicate all ourresources to building the PerfectProduct,” said Dhanani. He saysJasper has been instrumental inthese efforts by providing a wealthof knowledge from their experi-ence of over fifty-eight years inthe remanufacturing industry, andthe staff to implement it.

Dhanani says the BellinghamDistribution Center will store anddistribute products built inJASPER, including all gas anddiesel engines, transmissions, dif-ferentials, and marine stern drives.Dhanani says these products willbe distributed to JASPER cus-tomers throughout the Northwest,and bring JASPER’S qualityremanufactured drive line productsto the area.

JASPER Opens Remanufacturing &Distribution Center On West Coast

Jasper Engines & Transmissions President Doug Bawel(standing at left), and Vice President of Sales Tom Schrader(standing at right), joined local dignitaries in officially open-ing the Bellingham, Washington facility.

2

Borches Hi-Tech Auto Repair in Warren, MI, takes care of both fleet and personal vehi-cles. Borches ‘Bob’ Siljanovski (second from right), his technicians Sean and Alex, andhis Office Assistant Pat, have been together since the company’s opening in 1989. With agoal of achieving an annual growth rate of 10 to 12 percent, Bob says he will look formore technicians to keep with his facility’s rapid growth.

Borches Hi-Tech Auto Repair

Borches Hi-Tech Auto Repair inWarren, Michigan, is the story of anindividual working and living theAmerican Dream.

Yugoslavia-born Borche ‘Bob’Siljanovski came to the United Statesfrom Great Britain in 1971 when hewas 14. He always had a love for cars,so during high school he took nightclasses for three years at a mechanicsschool.

After finishing school, Bob workedfor a Chevrolet Dealership in Detroitfrom 1976 to 1989. He then openedBorches Hi-Tech Auto Repair onOctober 5th, 1989. When he firstopened, his shop was just 2,200 squarefeet. But the growth of his businessprompted an expansion in 1995 to itspresent size of 5,100 square feet. Theshop, located at 24601 Hoover Road inWarren, now has nine service bays andfour lifts, along with three ASECertified technicians, and two officepersonnel. Bob says the constant train-ing of he and his technicians is veryimportant. “If you don’t keep yourselfupdated, you’re out of business,” saysBob.

Borches Hi-Tech Auto Repair startedusing JASPER Remanufactured DriveTrain Products in 1992 to take care offleet and personal vehicles. Bob esti-mates he installs 12 to 14 gasoline

engines a year, along with a few trans-missions and differentials. Bob likesJASPER Remanufactured Productsbecause, as he puts it, “the productspeaks for itself.” Bob is aware thereare companies that will try and sellhim something. But he trustsJASPER not only for the quality ofthe product, but because of JASPER’Swarranty. Bob says if his customerstravel, “if there is a problem, JASPERstands behind them."

Bob says his repeat customers, bothfleet and individuals, are familiar withthe JASPER product, and he says hewants his customers to feel comfort-able when he deals with them.

Bob is also involved in many activi-ties to help the community. BorchesHi-Tech Auto Repair sponsors thelocal DARE program, BBA, theWarren Beautification Project, whichis organized to keep the city clean,and sponsor of children that partici-pate with the Warren PoliceDepartment.

The goal of Borches Hi-Tech is toachieve annual growth of ten totwelve percent, and with keeping hisfocus on education, quality, and thelocal involvement in his community,there’s no doubt he will continue toreach his goals.

Yes, bearings do and will wearout. Regardless of material anddesign advances, modern enginebearings are not indestructible.

By far the most common cause ofpremature bearing failure is thepresence of dirt in the engine. Ifthe vehicle is operated in extraordi-narily dirty conditions, or the vehi-cle owner fails to change the air fil-ter, engine oil and oil filter at prop-er service intervals, dirt will accu-mulate within the oil. Some finedirt particles will embed into thelining of the engine bearing. Keepin mind, however, that each particleis an addition to the lining material,potentially causing the bearing wallto thicken.

Larger hard particles, and exces-sive small particles, might onlypartially embed within the lining.In this case, the lining can

essentially hold the particle againstthe shaft, causing damage. In vir-tually all cases, bearings willbecome scored from the presenceof excessive dirt. The amount ofdistress depends on the type ofdirt, the amount of dirt, the oilclearances, bearing material, andthe engine operating conditions.

Insufficient lubrication is anothercause of bearing failure. This con-dition can cause “wiping” of thebearing, through which liningmaterial is picked up and rede-posited in another area of the bear-ing face. In severe conditions,there can be serious overheating ofthe bearing material in areas wherethe lining has been wiped away.

Insufficient lubrication can haveseveral causes: low engine oil sup-ply, a dry start following an over-haul, incorrect oil clearancesbetween the bearing and the shaft,inadequate oil pump delivery, amalfunctioning oil pressure reliefvalue, dilution of the oil with fuel(often caused by piston ring blow-by), dilution of the oil withantifreeze (defective head gasket,warped cylinder head and/orcracked block) and improper bear-ing installation.

The last point warrants specialattention. In many applications,the upper and lower main bearinghalves are identical and each canbe placed in either position. Inother applications, however, onebearing half might have an oil feedhole, while the other does not. Ifthese bearings are reversed, theresult will be oil starvation and

total failure of the bearing.Severe overloading from over-

revving the engine or luggingunder unusually heavy loads cancause surface spalling and fatiguecracking in ordinary bearings.Upper rod bearings and lowermain bearings showing signs offatigue stress (flaking and separa-tion of bearing layers from thesteel backing) may indicate a deto-nation or pre-ignition problem.Excessive oil clearances can alsobe a contributing factor to over-load failure.

Bearings can even fail due toexcessive idling. This type of fail-ure is due to poor oiling and inef-ficient oil f ilm formation causedby slow shaft speed and low pumpoutput, combined with the repeat-ed explosive forces produced bythe combustion process.

Corrosion is another issue worthexploring. Corrosion occurs, inmost cases, with copper alloybearings. Typically, the bearing’slead phase is attacked by someingredient of the oil. Some causesof the contamination are infre-quent engine operation, extendedoil change intervals, the use ofhigh-sulfur diesel fuels, extremelyhot operation, incompatible engineoils, using “sour” gas as fuel, andextreme piston/ring blow-by.

Durability and Bearing Wear: The TruthAbout Durability By Matt Barkhaus

Engine Bearing Product Planner Federal-Mogul Corporation

3

has twenty

years of

experience

with Federal-

Mogul. He

has been in

various dis-

Matt Barkhaus

tribution and marketing

functions within the North

American aftermarket busi-

ness. Matt is currently the

engine bearing product

planner within the Engine

Parts Marketing Team. His

product planning responsi-

bilities include bearings,

bushings, thrust washers

and connecting rods. This is

the second installment of

his story on selecting the

perfect bearing for every

application.

4

NewsletterArchives OnThe WebYou can now find technical

information and other articlesfrom past copies of the JASPERNews & Updates Newsletter.

Readers can access the articlesby logging on to www.jasperengines.com. Access to the arti-cles is available from our“What’s New” page.

JASPER has also improved itson-line catalog, so you canquickly obtain a price quote on agasoline engine or transmission.

And, of course, JASPER prod-uct videos can be viewed on theweb site. A video featuring anoverview of JASPER is availableon the home page, while individ-ual product videos are availableon the product pages. Thevideos are import and domesticgasoline engines, diesel engines,light-duty and mid-range trans-missions, stern drives and differ-entials and rear axle assemblies.

In order to view the videos,users will need Windows MediaPlayer. If this software is notinstalled on your computer, youcan download it at no chargefrom a link on the JASPER site.

Jasper’s New Videos Have Hit TheStreets

The next time your JASPERFactory Representative comes toyour business, ask to see the newJasper Engines & TransmissionsUpdate Videos. These short sub-ject movies will show you the lat-est remanufacturing processes atthe Jasper and Crawford facilities.

Here’s a brief description of thevideos your JASPER representa-tive has to show you:

•Gasoline Engine Updates - Thisvideo is an overview of each gasengine update, and provides thebenefits of each update for yourcustomer.

•Detonation & Pre-ignition -Defines the causes of detonationand pre-ignition, and offers trou-bleshooting assistance on where tolocate the problem.

•Transmission Cell Assembly -Shows how JASPER’S new cellassembly area remanufacturesFord AOD, E4OD, and C6 auto-matic transmissions.

•Axi-Line TransmissionDynamometer - Shows you, step-by-step, how this new computer-ized dynamometer tests a JASPERremanufactured transmission.

•Customer Video - This updatedvideo shows the advantages ofpurchasing a JASPER remanufac-tured product. This video is avail-able on VHS and DVD formats.

There will be additional videosin the future, as JASPER strives tokeep you up to date on the latestremanufacturing processes.

How To Handle Inquiries and BuildTrust over the Telephone

What do you do when you

receive a telephone inquiry

from someone you have never

spoken to before? Is it possi-

ble for you to sell that poten-

tial customer a JASPER

remanufactured product? The

answer is unquestionably

YES! But first, you have to

build a bond, or trust with

that customer before you can

quote the job.

In building trust, you should

ask questions that involve

your caller, such as, “Other

than the engine, is the car in

fair condition?” Make it a

point that you listen to what

your customer is saying.

Take the time to explain

what JASPER will do and

what you will do for them.

You should assume a consult-

ing role when you present a

JASPER product; use the fea-

tures and benefits of our

products, along with the

unique factors of your own

business - like your years

experience, the diagnostic

equipment in your shop, ref-

erences, etc. - to separate

your shop from your competi-

tors.

Your credibility as a quality

JASPER installer means a

great deal to your customer.

He, OR SHE, values your

opinions, knowledge and

experience to help them

make an informed decision

and purchase a product that

will meet or exceed their

expectations for quality,

value and reliability.

Be sure you have your

customer’s name, address,

telephone number and fax

number so you can follow

up with that person.

Then suggest to the caller

that they bring their vehicle

in to your shop, to verify its

condition and review their sit-

uation in person. Take as

much time as needed when

the customer comes to your

shop; continue to build rap-

port and trust with that per-

son. And, be sure your shop is

kept spotless and professional

in appearance.

This sounds like an exten-

sive amount of work. But the

results are worth the effort.

5

We Have Our Calendar Winners!

It was a tough selection

process from the dozens of

entries we received. But the

winning photographs have been

picked to grace the pages of the

2001 Jasper Engines &

Transmissions Calendar. Our

2001 winners are:

Jimmy & Mary Turner

Dunlap, TN

1956 Chevrolet Belair 2-door

Hardtop

Dennis Kunnath

Shelby Twp. MI

1970 Chevrolet Chevelle SS 454

Convertible

Albert & Anne Herold

Catonsville, MD

1958 Plymouth Savoy

Steve Martin, Jr.

Long Branch, NJ

1948 Chevrolet Pick-Up

Ray Harp

Hampton, VA

1946 Ford Truck

Gary & Linda Young

Millfield, OH

1930 Ford Model ‘A’

Justin Ramsden

Mt. Laurel, NJ

1967 Ford Mustang Fastback

Larry Webb

Toledo, OH

1970 Chevrolet Corvette

Jason Kelley

Toledo, OH

1983 Chevrolet S-10

Extended Cab

Roger Hunter

Huntingburg, IN

1972 Chevrolet Blazer

Convertible

Dennis & Jon Schick

Blue Island, IL

1968 Pontiac GTO

Bill Petruniak

Melvindale, MI

1965 Chevrolet Impala SS

Reggie Selleck

Buchanan, NY

1933 Ford Cabriolet

Honorable Mention

Jeff Bassett

Cedar Springs, MI

Entrants were required to

submit a color photograph, color

slide or color transparency of a

vehicle or application in which a

JASPER gas or diesel engine,

transmission, differential or

stern drive has been installed.

The vehicles were to be placed

in a “show” type setting when

photographed.

Entries were judged based on

adherence to the category: vehi-

cles and performance-oriented

cars and trucks; the appearance

of the equipment, and the quali-

ty of the photograph, slide or

transparency.

Congratulations to our win-

ners. They will receive a Jasper

Motorsports race jacket and a

$100 credit toward their next

purchase of an engine, trans-

mission, differential, or stern

drive. Our Honorable Mention

winner receives a JASPER

sweatshirt and a $50 credit

toward their next purchase of

one of the above mentioned

products. And all of our contest

entrants will receive an auto-

graphed JASPER race hat.

Pictured here are just a few of thisyears contest winners. For a look at allof the winners in full rich color, be sureto watch our website at www.jasperengines.com.

6

Any time you have a machiningprocess you create a surface texturethat will need to be measured. Tofully control and monitor themachining process, you need to beable to measure the surface finish.This is possible through the use ofa Profilometer (Figure 1).

The Profilometer is a device thatutilizes a fine stylus probe thatrides along the surface at a givensampling length measuring thepeaks and valleys that were left bythe machining. When measuring,make certain that the probe ispulling the stylus perpendicular tothe tooling grooves left frommachining. The measurements aretaken in microinches, or millionthsof an inch, so any flaw can give youan inaccurate reading. It’s a goodidea to take multiple readings indifferent locations when testing. Acenterline is set up by the pro-filometer using the measurementsof the peaks and valleys, then off ofthat centerline, the readings are cal-culated by the machine.

There are many variables whenmeasuring surface texture such asroughness, waviness, and lay.When all these are put together youget what is called a surface profile.The first component, roughness, isthe tool marks left behind aftermachining. The second, waviness,is not inherent to the machining

process, but it can be caused by outof balance cutters or vibration inthe machine itself. The third, lay, isthe surface pattern direction thatdepends on the machining process.Processes like turning, grinding,and drawing create a regular andmeasurable pattern.

When measuring the surface fin-ish with a profilometer, the surfaceprofile will be set to a particularparameter that best suits yourneeds. There are in excess of 150parameters that are being usedtoday throughout various indus-tries. The United States adopted,Root-Mean-Square (RMS) value,was one of the most popular para-meter used in recent years. Today,one of the more common parame-ters used in the U.S. is Roughnessaverage (Ra). Ra is the average ofthe values of the profile heighttaken within a specific samplinglength and measured from the pro-file centerline. Ra may be the mostpopular parameter, and an excellentway to monitor your process, but itis not always the best for what youare trying to achieve. As the namesuggests, it is an average. Thesame reading can describe two dif-ferent surfaces as illustrated inFigure 2. Both surfaces have thesame Ra readings but are in factvery different.

When analyzing a surface finish,

you need to take into considerationall of the factors that may be pre-sent. You may also need to usemultiple parameters to get an accu-rate profile of the surface.

(continued on next page)

A Brief Look Into Surface FinishesOn The Technical Side:

Figure 1 - The Profilometer utilizes a fine stylus probe that rides along the surface at a given sampling length, measuring the peaks and valleys that were left by the machining.

By Brian Campbell - Research and Development

has been

with JASPER

since 1992.

Brian is an

ASE Certified

Cylinder

Head Specia-

Brian Campbell

list. He started his career

with the Gas Engine Assem-

bly Department, then moved

to Research and Develop-

ment in February of 2000.

Brian’s responsibilities in-

clude random gas engine

audits to ensure quality and

performance of the product,

and the research of new

engine types, in preparation

for future production at

JASPER.

(continued from previous page)

As shown in Figure 2, a singlereading may not be adequate forthe situation. Other parameterssuch as Rpk (average peak height)or Rvk (average valley depth)would have shown a noticeabledifference, giving a more definedprofile. Rz, also known as theISO 10 point parameter, is anotherparameter that is growing in pop-ularity due to the accuracy that itprovides in assessing the peaksand valleys of the surface. This isaccomplished by measuring thedifference between the five high-est peaks and the five lowest val-leys and giving the averageheight.

The proper surface finish isvital to ensure the part will per-form properly and meet its lifeexpectancy. A good finish for oilretention may not be the best fin-

7

Figure 2 - Ra may be a popular parameter, and an excellent way to monitor your process, but it is not always the best for what you are trying to achieve. The same reading can describe two very different surfaces.

ish for a good seal, so finishesneed to be matched with what youare trying to accomplish. Oneexample of changing parametersdue to new materials in the auto-motive industry is the introductionof multi-layered steel head gaskets(M.L.S.).

An M.L.S. head gasket isdesigned to help limit the destruc-tion of the gasket from the shear-ing action between the head andthe block. This has become aproblem due to the use of dissimi-lar materials like cast iron and alu-minum for the block and heads.The different expansion rates ofthe two materials have causedsome problems in the past. TheM.L.S. gaskets minimize this bythe use of multiple layers of steelshims fastened together. The outerlayers are coated with a nitrile rub-ber, or a fluoroelastomer (Viton) tohelp with cold sealing. The com-

positions of these materials requirea very smooth surface to ensuresealing. With a traditional headgasket, we would like to see a sur-face finish of 60-100 Ra (400-800Rz). But for the new M.L.S. gas-ket, the finish should be a maxi-mum of 30 Ra (500Rz). Needingto achieve such a smooth surfacewith very little room for error hasmade it even more important to beable to measure the surface finishaccurately.

The art of surface finishes hasdeveloped into a specific and com-plex science, which is continuous-ly changing. With the growingnumber of parameters and newmaterials being used in today’smanufacturing, it is nearly a guar-antee that this technology willbecome even more complex in thefuture.

Do You Remember What You Read?So you say you read the JASPER News & Updates from cover to cover? Now you can see how much information

you’ve retained after you’ve read it. After you have answered the questions, simply clip out the coupon and send it tous. Each month we will take all the correctly answered coupons and randomly draw one out. The winner will receivea JASPER racing hat! Send to: Jasper Engines & Transmissions • P.O. Box 650 • Jasper, IN 47547-0650

Name ________________________________________________________Address ______________________________________________________City _____________________________ State_________ Zip Code ____________ Phone __________________

Jasper News & Updates - November Issue

1. Name the General Manger of the new Bellingham Facility? ________________________________________2. What is the most common cause of premature bearing failure? _____________________________________3. What are the three components of a surface profile? _____________________________________________4. What is Rpk? __________________________________________________

Prst. Std.U.S. Postage Paid

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JASPER ENGINE AND TRANSMISSION EXCHANGE815 Wernsing Road · P.O. Box 650 · Jasper, IN 47547-0650e-mail: sales@jasperengines.com

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