FZG Gear Testing Services for Automotive Applications

Intertek offers precision FZG (Forschungsstelle fur Zahnrader und Getriebebau) testing services to evaluate the load-carrying capacity, scuffing resistance, and wear characteristics of transmission fluids, gear oils, and drive system components. This internationally recognized gear testing methodology is critical for automotive OEMs, lubricant manufacturers, and component suppliers seeking to ensure the durability and performance of drivetrain systems under severe operating conditions.

FZG testing provides a controlled and repeatable platform to assess how lubricants perform under defined loads, speeds, and temperatures. The results help identify the relative strength of anti-wear and extreme pressure additives, thermal stability, and boundary lubrication behavior. These insights directly inform fluid formulation, component development, and approval programs for both automatic and manual transmission systems.

Applications and Industry Use Cases

FZG testing plays a vital role across:

• Automatic transmission fluid (ATF) development and validation
• Gear oil specification and formulation benchmarking
• OEM fluid approval programs
• Electric and hybrid drivetrain testing
• Friction material and synchronizer compatibility studies

The test data supports qualification efforts for Tier 1 suppliers and provides a foundation for performance comparisons, durability predictions, and warranty assurance.

FZG Test Methodologies Offered

We provide a broad range of FZG gear testing protocols, including:

ASTM D5182 – Standard Test Method for Evaluating the Scuffing Load Capacity of Lubricants Using the FZG Gear Rig

This method evaluates the scuffing performance of lubricants using a standard FZG A/8.3/90 gear test rig. It applies a progressive loading protocol until scuffing is observed on the gear tooth surfaces. The result is reported as the failure load stage, which quantifies the lubricant's resistance to surface distress under mixed and boundary lubrication regimes. It is especially useful for assessing EP (extreme pressure) additives and is a standard requirement in many OEM performance specifications.  The standard version of this test runs to load stage 12, using a 20mm A profile gear.  Each load stage is performed for 15 minutes, with an increase in the load for each load stage.  The test is terminated once a total of 20mm of scuffing/scoring on the teeth occurs, which yields the failure load stage.

ASTM D5182M LS14 – Modified Test Method for Evaluating the Scuffing Load Capacity of Lubricants Using the FZG Gear Rig

This method evaluates the scuffing performance of lubricants using a standard FZG A/8.3/90 gear test rig which is run per the standard procedure.  However, the modified version runs to Load Stage 14, allowing testing of fluids under more severe conditions that pass the standard version of the test at Load Stage 12.

ASTM D4998 – Standard Test Method for Evaluating Wear Characteristics of Lubricants Using the FZG Gear Rig

This procedure evaluates the gear wear protection properties of lubricants over extended operating periods. It uses defined load stages and test durations to assess the weight loss on gears, typically using the FZG C/8.4/90 procedure. This is particularly relevant for long-life lubricant applications where wear control under moderate load is critical.

FZG Step Load A10/16.6R/90 or 120: CEC L-084, ISO 14635-2 – Standard Test Method FZG Scuffing Load Carrying Capacity Test for High Ep Oils Using the FZG Gear Rig

The standard version of this test runs to load stage 10, using a 10mm A profile gear.  Each load stage is performed for 7.5 minutes, with an increase in the load for each load stage.  The test operates at a nominal speed of 2,910 rpm in a counter-clockwise gear rotation.  The test is terminated once a total of 20mm of scuffing/scoring on the teeth occurs, which yields the failure load stage.

CEC L-07-A-95 – FZG Gear Scuffing Test A/8.3/90

Widely accepted within the European automotive community, this test is aligned with the ASTM D5182 method but follows slightly different procedural details and performance thresholds. It provides a harmonized testing standard for European OEMs and lubricant approval programs. It is also employed in ACEA and ATIEL lubricant performance classifications.

FZG Pitting - C-PT Gears; FVA Information Sheet, Research Project No. 2/IV Using the FZG Gear Rig

This test is run for on a C profile gear and operates at a speed of 1,450 rpm in the forward direction at a temperature of 90°C.  Gear inspections occur every 24 hours to check for pitting.  If no pitting occurs, the test is restarted.  If pitting larger than 5 mm² is observed, the test is terminated.  The test will end at 300 hours if no pitting larger than 5 mm² occurs.

MERCON FZG – Standard Test Method for Evaluating Wear Characteristics of Lubricants Using the FZG Gear Rig

This test is based on the standard ASTM D5182, following that procedure but operates at modified temperatures of either 100°C or 150°C.  This test is a requirement in the Ford MERCON V specifications.

CEC L-84-02 – FZG Micropitting Test

This method investigates micropitting (also called gray staining) performance of lubricants. The test replicates the fatigue-induced surface damage mechanisms that can occur in high-load, rolling-sliding gear contacts, particularly in hypoid and helical gear sets. The test uses the FZG rig under conditions that promote microcrack formation and material fatigue. Results provide a rating of the lubricant's ability to prevent micropitting, which is critical for long-term gear integrity and NVH performance.

Additional Customized Testing

Intertek can adapt the FZG test rig to accommodate customer-specific requirements including modified gear sets, customized temperature or load profiles, or non-standard lubricants such as e-transmission fluids, biodegradable oils, or experimental additives.

Why Choose Intertek for FZG Testing

• ISO 17025 accredited laboratories
• Global network
• Decades of experience in gear system testing and fluid qualification
• OEM-trusted test programs supporting passenger vehicle, commercial, off-highway, and EV applications
• Technical consultation and tailored reporting

Let’s Get Started

Partner with us to strengthen your lubricant development, validate system durability, and meet evolving OEM specifications. Our team of drivetrain specialists will help you set up your FZG test plan and offer results that can translate into actionable engineering insights.