Product Families: Mechanic'S Tips
Product Families: Mechanic'S Tips
Product Families: Mechanic'S Tips
1000/2000
PRODUCT FAMILIES
ALLISON 4th GENERATION CONTROLS
2010 UPRATE
MT4007EN
Mechanic’s 2010 NOVEMBER
Tips MT4007EN
Allison Transmission
2010 Uprate
Allison 4th Generation Controls
1000 and 2000 Product Families
2
TABLE OF CONTENTS
TRADEMARK USAGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
IMPORTANT SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
LIST OF WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
SECTION 1. INTRODUCTION
1.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3
SECTION 3. REMOVING TRANSMISSION
3.1 DRAINING TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
3.2 DISCONNECTING CONTROLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
3.3 UNCOUPLING FROM DRIVELINE, ENGINE, AND VEHICLE . . . . . . . . . . . 43
3.4 REMOVING THE TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . 43
3.5 REMOVING THE FLEXPLATE ADAPTER . . . . . . . . . . . . . . . . . . . . . . 44
3.6 REMOVING OUTPUT FLANGE OR YOKE . . . . . . . . . . . . . . . . . . . . . 44
4
5.1.7 Crankshaft Hub Pilot or Adapter Concentricity . . . . . . . . . . . . . . . 56
5.1.8 Flexplate Bolt Hole Flatness . . . . . . . . . . . . . . . . . . . . . . . . . 56
5.1.9 Torque Converter Axial Location . . . . . . . . . . . . . . . . . . . . . . . 56
5.2 CHECKING FLEXPLATE DRIVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . 56
5.2.1 Flexplate Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
5.2.2 Engine Crankshaft End Play . . . . . . . . . . . . . . . . . . . . . . . . . 56
5.2.3 Flexplate Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . 56
5.3 CHASSIS AND DRIVELINE INSPECTION . . . . . . . . . . . . . . . . . . . . . . 56
5.4 COOLER, FILTER, AND LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
5.4.1 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
5.4.2 After Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
5.5 CHECKING CONTROLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
5.5.1 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
5.5.2 Throttle Position Sensor (TPS) Adjustment—Using Diagnostic Tool . . . 59
5.5.3 Hitch Pin Throttle Position Sensor Installation . . . . . . . . . . . . . . . 61
5
TRADEMARK USAGE
The following trademark is the property of the company indicated:
• Allison DOC® is a Registered Trademark of Allison Transmission, Inc.
6
IMPORTANT SAFETY INFORMATION
IT IS YOUR RESPONSIBILITY to be completely familiar with the warnings
and cautions in this manual. These warnings and cautions advise of specific
methods or actions that can result in personal injury, equipment damage, or
cause the equipment to become unsafe. These warnings and cautions are not
exhaustive. Allison Transmission could not possibly know, evaluate, or advise the
service trade of all conceivable procedures by which service might be performed
or of the possible hazardous consequences of each procedure. Accordingly,
ANYONE WHO USES A SERVICE PROCEDURE OR TOOL WHICH IS NOT
RECOMMENDED BY ALLISON TRANSMISSION MUST first be thoroughly
satisfied that neither personal safety nor equipment safety will be jeopardized
by the service methods used.
Vehicle manufacturers integrate Allison transmissions into vehicles used for a
variety of vocations and services. The vehicle manufacturer is responsible for
identifying the specific operating conditions to which the vehicle will be subjected
and to communicate the appropriate means for preventing unintended vehicle
movement within those conditions, in order to ensure vehicle and operator safety.
The vehicle owner and operator should be aware of and follow the vehicle
manufacturer’s operating instructions and warnings related to parking and
preventing unintended vehicle movement.
Proper service and repair is important to the safe and reliable operation of the
equipment. The service procedures recommended by Allison Transmission (or
the vehicle manufacturer) and described in this manual are effective methods for
performing service and diagnostic operations. Some procedures require using
specially designed tools. Use special tools when and in the manner recommended.
The WARNINGS, CAUTIONS, and NOTES in this manual apply only to the
Allison transmission and not to other vehicle systems which may interact with the
transmission. Be sure to review and observe any vehicle system information
provided by the vehicle manufacturer and/or body builder at all times the Allison
transmission is being serviced.
7
LIST OF WARNINGS
This manual contains the following warnings—
IT IS YOUR RESPONSIBILITY TO BE FAMILIAR WITH ALL OF THEM.
8
LIST OF WARNINGS (cont’d)
This manual contains the following warnings—
IT IS YOUR RESPONSIBILITY TO BE FAMILIAR WITH ALL OF THEM.
9
LIST OF WARNINGS (cont’d)
This manual contains the following warnings—
IT IS YOUR RESPONSIBILITY TO BE FAMILIAR WITH ALL OF THEM.
10
LIST OF WARNINGS (cont’d)
This manual contains the following warnings—
IT IS YOUR RESPONSIBILITY TO BE FAMILIAR WITH ALL OF THEM.
11
INTRODUCTION Section 1
1.1 INTRODUCTION
This manual is a mechanic’s reference for maintaining, removing, or installing
Allison 4th Generation Controls, 1000 and 2000 Product Families transmission
in a manner that assures satisfactory operation and long service life. All
features of the transmission and the vehicle involved in installation procedures
are discussed. For additional detailed information, refer to Service Manuals
(SM4006EN and SM5818EN) and Troubleshooting Manual (TS3977EN).
Unless indicated otherwise, this manual refers to all Allison 4th Generation
Controls 1000 and 2000 and 2010 Uprate Product Families transmissions.
The differences between the various transmissions are explained as required.
12
Figure 1–1. 1000 and 2000 Product Families—Cross
Section (With Park Pawl)
13
Figure 1–2. 2000 Product Family—Cross Section
14
Figure 1–3. 2000 Product Family—Cross Section (with Park Pawl)
15
Figure 1–4. 1000 and 2000 Product Family—2010 Uprate
16
Figure 1–5. 1000 and 2000 Product Families—LeftFront View
17
Figure 1–6. 1000 and 2000 Product Families—RightRear View
18
PREVENTIVE
Section 2
MAINTENANCE
19
2.1.3 Welding.
2.2 PROGNOSTICS
*
TES 389 fluids can only be used with Prognostics on January 2010 (or later) transmissions
and calibrated TCMs.
20
NOTE: To determine if your vehicle has Prognostics enabled,
observe operation of the OEMinstalled service indicator light.
This light illuminates for five seconds during startup in all vehicles
equipped with Prognostics. When Prognostics are enabled, the
service indicator light illuminates again for three seconds after the
initial fivesecond bulb check. If you are still unable to determine
whether your vehicle has Prognostics enabled, consult your OEM
service department or an authorized Allison distributor or dealer.
2.2.2 Oil Life Monitor (OM). The TRANS SERVICE indicator illuminates
when the remaining fluid life reaches approximately 2 percent (the parameter
begins at 100 percent moving downward towards the lowest threshold),
indicating the required change of the transmission fluid. The TRANS
SERVICE indicator is lit steadily upon each initialization of the TCM, and
remains on for approximately two minutes after the initial selection of a drive
range, until service is performed and the indicator is reset.
21
The TRANS SERVICE indicator can be reset with the Allison DOC® For
PC–Service Tool. It may also be reset by selecting N (Neutral)D (Drive)N
(Neutral)D (Drive)N (Neutral)R (Reverse)N (Neutral) on the shift selector,
pausing briefly (less than three seconds) between each selector movement,
with the ignition on and the engine not running. More details are provided in
applicable Allison service literature for your specific transmission model.
Failure to perform maintenance and reset the TRANS SERVICE indicator
within the next 100 hours of transmission operation will result in the
illumination of the CHECK TRANS light (in addition to the TRANS SERVICE
light). Any time this light is illuminated, the TCM registers a Diagnostic Trouble
Code (DTC), which requires the use of Allison DOC® For PC–Service Tool
to clear the code.
In addition to viewing DTCs, the Allison DOC® For PC–Service Tool may
also be used to display the amount of transmission operation from the initial
service indication until the service reset.
2.2.3 Filter Life Monitor (FM). The TRANS SERVICE indicator flashes
beginning with the first TCM initialization after reaching the time and mileage
parameters, indicating the filter has reached the end of its designed life. The
indicator continues to flash for two minutes after D (Drive) has been selected.
Thereafter, the indicator illuminates and flashes upon each TCM initialization,
continuing to flash for two minutes after the selection of D (Drive) each time,
until service is performed and the indicator is reset.
The TRANS SERVICE indicator can be reset with the Allison DOC® For
PC–Service Tool. It may also be reset by selecting N (Neutral)R (Reverse)N
(Neutral)R (Reverse)N (Neutral)D (Drive)N (Neutral) on the shift selector,
pausing briefly (less than three seconds) between each selector movement,
with the ignition on and the engine not running. More details are provided in
applicable Allison service literature for your specific transmission model.
Failure to perform maintenance and reset the TRANS SERVICE indicator after
an additional 100 hours of transmission operation results in the illumination of
the CHECK TRANS light (in addition to the TRANS SERVICE light). Any time
this light is illuminated, the TCM registers a DTC, which requires the use of
Allison DOC® For PC–Service Tool to clear the DTC.
In addition to viewing DTCs, the Allison DOC® For PC–Service Tool may
also be used to display the amount of transmission operation from the initial
service indication until the service reset.
22
2.2.4 Transmission Health Monitor (TM). The TRANS SERVICE indicator
illuminates, indicating the need for clutch maintenance, when the remaining
clutch life reaches approximately 10 percent, or if the running clearance
exceeds a maximum value which may indicate a nonwearrelated issue.
The indicator is lit steadily upon initialization of the TCM, and remains on at
all times, continuing to operate in this manner until service is performed and
the indicator is reset. If reset does not occur within 100 hours, the CHECK
TRANS light is illuminated (in addition to the TRANS SERVICE light) and the
TCM registers a DTC.
The indicator resets automatically upon elimination of the clutch clearance
condition which initiated it. The indicator can also be reset using the Allison
DOC® For PC–Service Tool if necessary.
In addition to viewing DTCs, the Allison DOC® For PC–Service Tool may be
used to display the amount of transmission operation from the initial service
indication until the service reset.
23
2.4 TRANSMISSION FLUID CHECK
24
WARNING: For vehicles containing 2000 Product Family
transmissions without autoapply parking brakes, each time you park
the vehicle or leave the operator’s station with the engine running,
do the following:
1. Bring the vehicle to a complete stop using the service brake.
2. Make sure that the engine is at low idle rpm.
3. Put the transmission in N (Neutral).
4. Apply the emergency brake and/or parking brake, and make
sure it is properly engaged.
5. If the operator’s station will be unoccupied with the engine
running, chock the wheels and take any other steps necessary
to keep the vehicle from moving.
If this procedure is not followed, the vehicle can move suddenly and
you or others could be injured.
NOTE: For accurate fluid level checks, be sure the fill tube and
dipstick meet Allison Transmission specifications.
Figure 2–1 shows the current dipstick markings for both deep
and shallow pans used on transmissions prior to January 2010
Uprate. These markings can also be used with January 2010 Uprate
transmissions, but it is recommended that January 2010 Uprate and
later transmissions use Figure 2–2 (shallow) and Figure 2–3 (deep).
After January 2011, all transmissions will be required to use
Figure 2–2 (shallow) and Figure 2–3 (deep).
25
26
Figure 2–1. Deep and Shallow Pan Dipstick Calibration Markings—May be Used with
Transmissions Built Prior to January 1, 2011
27
Figure 2–2. Shallow Pan Dipstick Calibration Markings—Recommended for use with Transmissions with
build dates from January 1, 2010 and Required for Transmissions with build dates from January 1, 2011
28
Figure 2–3. Deep Pan Dipstick Calibration Markings—Recommended for use with Transmissions with build
dates from January 1, 2010 and Required for Transmissions with build dates from January 1, 2011
2.4.1 Manual Fluid Check Procedure. Clean all dirt from around the top of
the fluid fill tube before removing the dipstick. Do not allow dirt or foreign
matter to enter the transmission. Dirt or foreign matter in the hydraulic system
may cause undue wear of transmission parts, make valves stick, and clog
passages. Check the fluid level using the following procedure and report any
abnormal fluid levels to your service management.
2.4.2 Cold Check Procedure. The purpose of the cold check is to determine
if the transmission has enough fluid to be operated safely until a hot check
can be made.
29
(5) Chock the wheels and take any other steps necessary to
keep the vehicle from moving.
c. For vehicles containing 2000 Product Family transmissions
without autoapply parking brakes:
(1) Bring the vehicle to a complete stop on a level surface using
the service brake.
(2) Make sure the engine is at low idle rpm.
(3) Put the transmission in N (Neutral).
(4) Apply the emergency brake and/or parking brake and make
sure they are properly engaged.
(5) Chock the wheels and take any other steps necessary to
keep the vehicle from moving.
2. Run the engine for at least one minute. Apply the service brakes and
shift to D (Drive), then to N (Neutral), and then shift to R (Reverse) to
fill the hydraulic system. Finally, shift to P (Park) or PB (AutoApply
Parking Brake), if available, or N (Neutral) and allow the engine to idle
500–800 rpm. Slowly release the service brakes.
3. With the engine running, remove the dipstick from the tube and wipe
the dipstick clean.
4. Insert the dipstick into the tube and remove. Check the fluid level
reading. Repeat the check procedure to verify the reading.
5. If the fluid level is within the COLD CHECK band, the transmission may
be operated until the fluid is hot enough to perform a HOT RUN check.
If the fluid level is not within the COLD CHECK band, add or drain as
necessary to bring it to the middle of the COLD CHECK band.
6. Perform a hot check at the first opportunity after the normal operating
sump temperature of 71°C–93°C (160°F–200°F) is reached.
30
and the transmission has been operated under load for at least
one hour.
2. Park vehicle as follows:
a. For vehicles containing 1000 and 2000 Product Families
transmissions with park pawl:
(1) Bring the vehicle to a complete stop on a level surface using
the service brake.
(2) Make sure that the engine is at low idle rpm.
(3) Put the transmission in P (Park).
(4) If a parking brake is present, apply the parking brake. Make
sure the parking brake is properly engaged.
(5) Engage the P (Park) range by slowly releasing the service
brake.
(6) Apply the emergency brake, if present, and make sure it is
properly engaged.
(7) Chock the wheels and take any other steps necessary to
keep the vehicle from moving.
b. For vehicles containing 2000 Product Family transmissions with
autoapply parking brakes:
(1) Bring the vehicle to a complete stop on a level surface using
the service brake.
(2) Make sure the engine is at low idle rpm.
(3) Put the transmission in PB (AutoApply Parking Brake).
Make sure the parking brake is properly engaged.
(4) Apply the emergency brake, if present, and make sure it is
properly engaged.
(5) Chock the wheels and take any other steps necessary to
keep the vehicle from moving.
c. For vehicles containing 2000 Product Family transmissions
without autoapply parking brakes:
(1) Bring the vehicle to a complete stop on a level surface using
the service brake.
(2) Make sure the engine is at low idle rpm.
(3) Put the transmission in N (Neutral).
(4) Apply the emergency brake and/or parking brake and make
sure they are properly engaged.
31
(5) Chock the wheels and take any other steps necessary to
keep the vehicle from moving.
3. With the engine running, remove the dipstick from the tube and wipe
clean.
4. Insert the dipstick into the tube until it stops. Then remove it. Check fluid
level reading. Repeat the check procedure to verify the reading.
NOTE: Safe operating level is within the HOT RUN band on the
dipstick. The width of the HOT RUN band represents approximately
1.0 liter (1.06 quart) of fluid at normal operating sump temperature.
5. If the fluid level is not within the HOT RUN band, add or drain as
necessary to bring the fluid level to within the HOT RUN band.
2.4.4 Consistency of Readings. Check the fluid level at least twice while
the engine is running. Consistency (repeatable readings) is important to
maintaining accuracy of the readings. If readings are inconsistent, check the
transmission breather to make sure it is clean and unclogged. If inconsistent
readings persist, contact your nearest Allison distributor or dealer.
32
CAUTION: Disregarding minimum fluid temperature limits can result
in transmission malfunction or reduced transmission life.
When choosing the optimum viscosity grade of fluid to use, duty cycle,
preheat capabilities, and/or geographic location must be taken into
consideration. The table below lists the minimum fluid temperatures at which
the transmission may be safely operated without preheating the fluid. Preheat
with auxiliary heating equipment or by running the equipment or vehicle with
the transmission in P (Park) or PB (AutoApply Parking Brake), if available, or
N (Neutral) for a minimum of 20 minutes before attempting range operation.
Shifting is inhibited and torque converter clutch mode is not reached until the
transmission fluid operating temperature requirements have been met. Refer
to Table 2–1 . As the transmission reaches normal operating temperature, all
shift ranges and the torque converter clutch mode begin to function.
2.7.1 Frequency. New vehicles delivered from the OEM with a mixture of
Allisonapproved TES 295 fluid and nonTES 295 fluids, or Schedule 1 TES
389 Allison Transmission approved fluids, must follow fluid/filter change
recommendations outlined in Schedule 1.
If the customer fills the transmission with Allison approved TES 295 fluid, the
change recommendations of Schedule 1 must be followed.
Upon the next oil change, if the customer reinstalls Allison approved TES 295
fluid, the fluid/filter change recommendations outlined in Schedule 2 may
33
be used. The recommendations in Schedule 2 are based upon Allison fluid
change procedures and the transmission containing 100 percent concentration
of Allison approved TES 295 fluid. For transmissions that contain a mixture of
Allison approved TES 295 fluid and nonTES 295 fluids, refer to Schedule 1.
New vehicles delivered from the OEM with Allison approved TES 295 fluids
and Allison Prognostics, beginning with MY09 must follow fluid/filter change
recommendation outlined in Schedule 3. Allison Prognostics must only be
used with Allison approved TES 295 fluid and Allison Control Main Filter
P/N 29539579.
Allison Transmission requires an initial filter change for the SpinOn Control
Main Filter during the first 16 000 km (10,000 miles) or 400 hours of service,
whichever comes first. Refer to the Recommended Fluid and Filter Change
Intervals schedules for recommendations. The transmission sump filter is
permanent and does not require replacement except at overhaul.
Severe Vocations are defined as vehicles experiencing duty cycles that
require stopping more than once in a mile. General Vocations include all other
vocations. Local conditions, severity of operation, or duty cycle may require
more or less frequent fluid change intervals that differ from the published
recommended fluid change intervals of Allison Transmission.
The following tables are given only as a general guide for fluid and filter
change intervals.
34
Table 2–2. Schedule 1. Recommended Fluid and Filter Change
Intervals (Allison Approved NonTES 295 Fluids)
Filters
Vocation Fluid* Control Main** Internal Lube/Auxiliary
80 000 km 80 000 km 80 000 km
(50,000 Miles) (50,000 Miles) (50,000 Miles)
General Overhaul
24 Months 24 Months 24 Months
2000 Hours 2000 hours 2000 hours
20 000 km 20 000 km 20 000 km
(12,000 Miles) (12,000 Miles) (12,000 Miles)
Severe Overhaul
6 Months 6 Months 6 Months
500 hours 500 hours 500 hours
*Allison approved nonTES 295 fluid is defined as the quantity of oil remaining in the
transmission after a standard fluid change combined with the quantity of Allison approved
TES 295 fluid that is required to fill the transmission to the proper level. A mixture of Allison
approved TES 295 fluid vs. nonTES 295 fluids other than as defined in this paragraph
does not meet the requirements that permit the eligibility for the recommendations given
in Schedule 2.
**Control Main Spinon Filters Only—Initial 16 000 km (10,000 miles) or first engine oil
change, whichever comes first.
35
Table 2–4. Schedule 3. Recommended Fluid and Filter Change Intervals
(Allison Prognostics “ON” Beginning in MY09 Using 100 Percent
Concentration of Allison Approved TES 295 Fluids)
Filters
Vocation Fluid* Control Main** Internal Lube/Auxiliary
Change fluid Change filter Change filter
when indicated when indicated when indicated
General or by controller by controller by controller
Overhaul
Severe or 48 months, or 48 months, or 48 months,
whichever whichever whichever
comes first. comes first. comes first.
*MY09 Allison Prognostics must only be used with Allison approved TES 295 fluid.
**Allison Prognostics must only be used with Allison Control Main Spinon Filter P/N 29539579.
Control Main Spinon Filters Only—Initial 16 000 km (10,000 miles) or 400 hours, whichever
comes first.
36
2.7.3 Fluid Analysis. Transmission protection and fluid change intervals
can be optimized by monitoring fluid oxidation according to the tests and
limits shown in the following table. Fluid oxidation can be monitored through
a fluid analysis firm and/or by using an oil analysis kit. Allison Transmission
recommends that customers use fluid analysis as the primary method for
determining fluid and filter change intervals. In the absence of a fluid analysis
program the fluid change intervals listed in Schedules 1, 2, 3 or 4 should
be followed.
• Fluid analysis firms—Consult your local telephone directory for fluid
analysis firms. To make sure fluid analysis is consistent and accurate,
use only one fluid analysis firm. Refer to the Technician’s Guide for
Automatic Transmission Fluid, GN2055EN, for additional information.
• Oil analysis kits, P/N 29537805, are available through your normal
Allison Transmission parts source.
Refer to the Technician’s Guide for Automatic Transmission Fluid, GN2055EN,
for additional information.
2.8.1 Fluid Examination. At each fluid change, examine the drained fluid for
evidence of dirt or water. A normal amount of condensation (not to exceed 0.2
percent) will appear in the fluid during operation.
37
2.8.3 Engine Coolant.
2.8.4 Metal. Metal particles in the fluid (except for the minute particles
normally trapped in the oil filter) indicate internal transmission damage. If
these particles are found in the sump, the transmission must be disassembled
and closely inspected to find their source. Metal contamination requires
complete transmission disassembly. Clean all internal and external hydraulic
circuits, cooler, and all other areas where the particles could lodge.
NOTE: When equipment to flush the oil cooler is not available, install
a filter in the cooler line between the oil cooler and the transmission
“from cooler” port. The cooler circuit pressure drop specifications
must still be met (see AS64071 or AS64072 in the Allison Sales
Tech Data book SA3018EN). Frequent initial changes of this filter
element may be required as debris is flushed out of the oil cooler
circuit. Closely monitoring change in cooler circuit pressure drop will
indicate when a filter change is needed.
38
2.9.2 Replace Control Main Filter. Refer to Figure 2–4 during the following
procedure.
1. Remove the control main filter by rotating it counterclockwise. Use a
standard straptype filter wrench.
2. Remove the magnet from the filter attachment tube or from the top
of the filter element.
3. Clean any metal debris from the magnet. Report any metal pieces
larger than dust to your service management.
4. Reinstall the magnet onto the filter attachment tube.
5. Lubricate the gasket on the control main filter with transmission fluid.
6. Install, by hand, the control main filter until the gasket on the filter
touches the converter housing or cooler manifold.
CAUTION: Turning the control main filter more than ONE FULL
TURN after gasket contact will damage the filter.
7. Turn the filter ONE FULL TURN ONLY after gasket contact.
8. Reinstall the drain plug and sealing washer. Tighten the drain plug to
30–40 N∙m (22–30 lb ft).
39
Figure 2–4. Replacing Control Main Filter
2.9.3 Refill Transmission. Refer to Table 2–7 for fluid refill quantities. The
amount of refill fluid is less than the amount used for the initial fill. Fluid
remains in the external circuits and transmission cavities after draining the
transmission.
After refill, check the fluid level using the procedure described in
2.4 TRANSMISSION FLUID CHECK.
40
Table 2–7. Transmission Fluid Capacity
Sump Initial Fill Refill
Liters Quarts Liters Quarts
Standard 14 14.8 10 10.6
Shallow 12 12.7 7 17
2.10 BREATHER
41
REMOVING
Section 3
TRANSMISSION
3. Disconnect all hydraulic lines from the transmission. Remove the lines
from the vehicle if they interfere with transmission removal. Plug all
openings to keep dirt from entering the hydraulic system.
42
3.3 UNCOUPLING FROM DRIVELINE, ENGINE, AND VEHICLE
5. Remove all bolts, nuts, washers, spacers, and supports attaching the
transmission to the vehicle and the engine.
43
2. Raise or lower the transmission as necessary to remove it from the
vehicle.
44
TRANSMISSION
Section 4
PREPARATION
4.1.1 Bolt Holes. Check all bolt holes on the front of the transmission and
rear of the engine that are used in connecting the transmission to the engine.
The threads must be undamaged and the holes free of chips or foreign
material.
4.1.2 Pilot Boss. Check the pilot boss (at the center of the flywheel) for
damage or raised metal that prevents free entry into the crankshaft hub (or
adapter).
4.1.3 Starter Ring Gear. Check the starter ring gear for excessive wear
or damage.
4.2.1 Output Oil Seal. Check the output oil seal for leaks or damage. Refer
to GN4008EN, InChassis Maintenance, for replacement instructions. If not
replacing the oil seal, lubricate it with hightemperature grease or transmission
fluid.
45
4.2.2 Check Flange or Yoke. Check each flange or yoke for damage or
wear. The oil seal contact surface must be smooth and regular to prevent oil
leaking past the seal. Rotate the flange after installation to check for binding.
1. Lubricate the splines of the output shaft and the oil seal assembly with
transmission fluid or oilsoluble grease.
2. Start the output flange or yoke assembly onto the output shaft, ensuring
the splines are properly engaged and slide freely. Push the output
flange or yoke assembly into the rear cover module.
3. Install a new output shaft sealing washer and output shaft bolt.
46
NOTE: DO NOT use sealing compounds—they are usually
incompatible with automatic transmission fluid.
4.3.1 Install Guide Pins. Guide pins are included in the PTO manufacturer’s
installation kit.
Determine the required position of the guide pins in relation to the mounted
position of the PTO. Install two headless guide pins into the main housing
PTO pad. Tighten the pins.
4.3.2 Install Gasket. Install the special gasket over the guide pins—ribbed
surface away from the transmission.
Mount the PTO on the guide pins or studs provided in the PTO kit. Mesh the
PTOdriven gear with the transmission PTO drive gear. Retain the PTO by
installing a bolt in the top bolt hole. Install the remaining bolts and nuts, if
used. When nuts are not used, two bolts replace the guide pins. Tighten all
bolts to 57–68 N∙m (42–50 lb ft). Tighten nuts to manufacturer’s specifications.
Be sure PTO backlash meets manufacturer’s requirements.
Make sure there is an opening of 0.81 mm (0.032 inch) in the line in order
to control the amount of fluid diverted from the transmission. Some PTO
assemblies contain internal restrictions equivalent to the required orifice
(check with the PTO manufacturer for lubrication needs and the orifice
installation). This connection can be made later if the lube line will interfere with
transmission installation. Refer to Figure 4–2 which shows this connection.
47
Figure 4–1. Cooler Port and Main Pressure Tap Location
48
Figure 4–2. PTO Lube Plumbing Schematic
49
Figure 4–3. PTO Clutch Pressure Plumbing Schematic
4.4.1 Location.
The fill tube may be mounted on either the right or left side. The unused fill
tube provision must have a plug to fill the tube opening.
50
CAUTION: Install the fill tube bracket with the correct length M8
selftapping screw which is 24.0 mm (0.95 inch). A screw that is
too long may cause cracks and leaks in the main housing. Refer
to AS64065 in the Allison Sales Tech Data Book on the Allison
Extranet for the correct screw specifications.
4.4.2 Installation.
If the fill tube interferes with the installation of the transmission, delay these
steps until after the transmission is in the vehicle.
1. Install the fill tube seal into the main housing.
2. Insert the fill tube through the seal until the shoulder at the bottom of the
fill tube contacts the seal.
3. Align the tube bracket with its bolt location.
4. Install the fill tube bolt and tighten until it is firmly seated against the
bracket.
4.5.4 Cleanliness. Check the openings into which the cooler lines connect
for deformities or obstructions. Check the transmission electrical connectors
for cleanliness. Clean electrical connectors with LPS cleaner only (refer
to SIL 17TR94).
51
PREPARING
VEHICLE FOR
Section 5
TRANSMISSION
INSTALLATION
5.1.2 Flywheel Housing Pilot Bore Diameter. The flywheel housing pilot
bore diameter must measure:
• No. 3 Housing—409.58–409.70 mm (16.125–16.130 inches)
• No. 2 Housing—447.68–447.81 mm (17.625–17.630 inches)
52
Figure 5–1. Engine Adaptation (No. 3 Housing)
53
Figure 5–2. Engine Adaptation (No. 2 Housing)
54
Figure 5–3. Typical Arrangement of Adaptation Components
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5.1.7 Crankshaft Hub Pilot or Adapter Concentricity. The crankshaft hub
pilot or the hub adapter pilot concentricity cannot exceed 0.25 mm (0.010
inch) TIR.
5.1.8 Flexplate Bolt Hole Flatness. Flexplate bolt hole flatness must be
0.76 mm (0.030 inch) TIR, or less, when measured at 292 mm (11.5 inches)
diameter.
5.2.2 Engine Crankshaft End Play. Make sure engine crankshaft end play
is within the engine manufacturer’s specifications.
5.2.3 Flexplate Assembly Installation. Install the flexplate onto the engine
crankshaft hub using the bolts and torque values specified for that engine.
Refer to Figure 5–1, Figure 5–2, or Figure 5–3 for the proper position of an
installed flexplate.
56
• Driveline angles—runout, or balance which does not conform to the
manufacturer’s recommendations
• Driveline yoke slip joints:
– freedom of movement
– damaged or wornout
– correctly lubricated
– correctly indexed
• Driveline midship or hanger bearings—damaged or misaligned
• Universal joints:
– freedom of movement
– damaged or wornout
– correctly lubricated
– correctly indexed
• Vehicle differential backlash—manufacturer’s specification
• Universal joint coupling—alignment and differential damage
• Crossframe members and rear support members—condition and
location
• Auxiliary transmission:
– shaft alignment
– alignment of yoke or flange
– backlash
– fluid leaks
5.4.1 Inspection.
Tools Required
• J 46550A Transmission Cooler Kwik Cart
Perform the following and correct any faulty conditions:
• Transmission fluid cooler and related coolant lines:
– Check for contamination—clean and flush as necessary
– Inspect for deterioration
– Inspect for faulty connectors or kinks
57
– Clean and flush transmission fluid cooler, both coolant and oil sides
using J 46550A Transmission Cooler Kwik Cart. Pressure check
both sides using a 276 kPa (40 psi) air supply.
• Hydraulic lines:
– Check for contamination—clean and flush as necessary
– Inspect for deterioration
– Inspect for faulty connectors or kinks
5.5.1 Inspection.
Inspect the following and correct any faulty conditions:
• Shift selector:
– improper operation
– poor electrical connections
– improper harness routing
• Cab and chassis wiring harness:
– poor electrical connections
– frayed insulation
– wiring damage
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• Throttle sensor components, if present:
– freedom of movement
– improper routing
– bellows damage
– improper or loose cable mounting
• PTO controls, if present:
– damage
– wear
– improper operation
– lubrication
– electrical harness connections and wiring damage
• Temperature gauge:
– capillary tube damage (if used)
– sensor damage
• Fluid pressure gauge tubing:
– damage
– kinks
– improper routing
59
Figure 5–4. Hitch Pin Throttle Position Sensor Installation Diagram
60
5.5.3 Hitch Pin Throttle Position Sensor Installation.
1. Install the throttle sensor body as follows:
a. Clamp cable end using clamp and shims (Figure 5–4).
b. Secure the sensor body using the mounting holes provided.
c. Install a heat shield if any part of the throttle sensor is near the
exhaust manifold, turbochargers, or any other heat source.
2. Adjust the throttle sensor as follows:
a. The engine fuel lever must be at the closed throttle position.
b. Install the hitch pin cable end of the sensor to the engine fuel
lever with brackets so that at the idle position the cable end is
11–17 mm (0.44–0.67 inch) from its fully retracted position, and at
wide open throttle the cable end is pulled an additional 15–22.9
mm (0.60–0.90 inch) from the idle position.
c. Recheck the stroke distance of the throttle sensor, from closed
to wide open after installation is completed. Check the stroke
distance of the throttle sensor, from closed to wide open. Stroke
distance must be from 15–22.9 mm (0.60–0.90 inch).
d. Recheck for zero clearance at the fuel lever. Make sure the
15.2–22.9 mm (0.60–0.90 inch) dimension has not changed.
e. Design throttle sensor linkage brackets and levers to nominal
dimensions so the system stays within tolerance bands
throughout its operating life.
61
INSTALLING
TRANSMISSION Section 6
INTO VEHICLE
6.1 HANDLING
62
3. Attach the flexplate adapter to the front of the torque converter or to the
flexplate using six new adhesivecoated M10 x 1.5 x 15 bolts. Tighten
each bolt to 57–68 N∙m (42–50 lb ft).
4. Align one of the flexplate’s bolt holes with the access opening in the
engine flywheel housing.
5. Lubricate the center pilot boss with molybdenum disulfide grease
(Molycote G, or equivalent).
6. Install an M10 x 1.5 headless guide bolt into one of the flexplate bolt
holes in the flexplate adapter or torque converter mounting lug (refer to
Figure 6–1). Align the guide bolt with the flexplate hole at the access
opening.
63
10. Install all transmissiontoengine bolts and washers fingertight (a
minimum of 10 bolts is required and must include the top two).
64
6.5 CONNECTING POWER TAKEOFF CONTROLS
If not already mounted, mount the PTO(s) onto the transmission (refer to
4.3 INSTALLING PTO).
1. Check the PTO harness routing for kinks and sharp bends. Avoid
routing the cable close to exhaust pipes or manifold. The PTO harness
must not rub or interfere with adjacent parts.
2. Connect controls to the PTO.
3. Check for proper PTO control operation.
4. Couple the PTO output to its driven equipment. Check couplings
or universal joints for correct assembly and alignment. If the driven
component is not a direct mount arrangement, check the PTO drivelines
for angularity, phasing, and offsets.
65
Figure 6–2. Cooler Port Location
1. The transmission has a sump fluid thermistor on the pressure switch
manifold. Actual temperature readings may be viewed using the Allison
DOC® For PC–Service Tool. Refer to the Allison DOC® For PC–Service
Tool User’s Guide, GN3433EN, furnished with the tool.
2. A temperature gauge may be installed in the “To Cooler” line. If
equipped, install a temperature probe, capillary tube and bulb or a
thermocouple.
a. If equipped with a capillary tube and bulb:
(1) Tighten the adapter tight enough to prevent leakage.
(2) Install the bulb into the adapter and tighten the nut.
(3) Check the capillary tube for interference with other parts that
might chafe or damage the tube. Long tubes may require
support clips or brackets.
b. If equipped with a thermocouple, install the thermocouple and
connect the leads.
66
2. If PTO(s) is (are) used, connect the PTO(s) wiring harness(es). The
PTO connector is NOT part of the Allison Transmission external wiring
harness.
3. Connect linkage to the transmission shift lever. For information on
adjusting the shift linkage, refer to the SHIFT SELECTOR CABLE
LINKAGE section of the InChassis Maintenance guide GN4008EN.
4. If used, connect wire(s) to electric tachograph.
5. Make sure the speed sensors, the PTO connector, and all other
connectors are securely seated and latched. A connector can be
heard or felt when it latches, but confirm the latching by pulling on the
connector—NOT THE WIRES.
6. If parking brake is present, connect linkage.
67
– Speed sensor bolts—10–13 N∙m (7–10 lb ft)
– Output flange bolt—108–136 N∙m (80–100 lb ft)
– PTO cover bolts—40–45 N∙m (29–33 lb ft)
– PTO mounting bolts—57–68 N∙m (42–50 lb ft)
– Selector lever nut (customersupplied)—20–27 N∙m (15–20 lb ft)
– PTO pressure hose fitting to transmission—10–13 N∙m (7–10 lb ft)
– Rear cover bolts—51–61 N∙m (38–45 lb ft)
– TPS to engine bracket (M6 bolts)—10–13 N∙m (7–10 lb ft)
(0.250–20 bolts)—12–15 N∙m (9–11 lb ft)
• Cooler Fluid Lines and Air Hose for:
– No leaks
– Connection tightness
– Correct routing
• Throttle Sensor for:
– Proper adjustment
– Correct routing of cable and harness
• Driveline for:
– Proper indexing of universal joints
– Proper drive shaft angles
– Driveline backlash
– Lubricated universals and slipjoints
• Hydraulic System for:
– Recommended fluid (refer to 2.6 FLUID RECOMMENDATIONS and
2.7 TRANSMISSION FLUID AND FILTER CHANGE INTERVALS)
– Correct fluid level in transmission
– Dipstick correctly calibrated
– Fill tube tight
– Fill tube cap tight
– Breather clean and free of restrictions
– No fluid leaks during operation
• Instruments and Electrical Equipment for:
– Proper wiring and electrical connections
– Instruments, gauges, and lights work correctly
68
– Shift selector display is on and CHECK TRANS light is off
– Fluid temperature gauge
• Power Takeoff, if installed, for:
– Controls connected and operative
– Correctly coupled to driven equipment
– Lubrication line correctly installed and routed, if used
– Clutch apply line correctly installed and routed, if used
6.11.1 Driveability.
69
7. Troubleshoot—if DTCs exist after the road test, find and correct
problems (refer to TS3977EN, 1000 and 2000 Product Families
Troubleshooting Manual).
70
• Comments:
71
CUSTOMER
Section 7
SERVICE
72
NOTES
73
NOTES
74
NOTES
75
MT4007EN 201011 Printed in USA