- Allison Transmissions
Contents
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3. Em HH EJ Jr 3 Cn gt In T SNISNOH H31H3ANO2 ued mojjeys pue BuisnoH 2 Jeuondo NOILO3S 55043 S3ITllNV43 LONGOUd 0000 0001 vii 1NOHU3 1331 NOISSINSNVYL S3ldi v3 LONGOYd 0000 ANY 0001 dall 710 NIVIN PEN NOILV201 Hagni Ti 110 UaTavilvAV HV35 Old 02108 9 3VS l3VHS 90199735 ERU HOLIMS NASN 05 35 03395 114100 2 S 55 9NuNnOW lt Uaxvug 9NDIuVd JINJA 110 SN MJA NOISSINSNVHL 5 LONGOYd 0000 ANY 0001 0193 02 91 19313 NIVIN aN YY39 HOSN3S 43395 Old uq3r1ddns u3Woisno 01108 9 3VS 804 NOISIAOUd NOILV201 Tii 110 Ua18vilvAv S1HOd 831002 1 5 6 3VS SNILNNOW uOSN3S 03345 104100 ELN3A 710 uOSN3S Ed33dS 3NIguni uOSN3S 83385
4. GUIDE BOLT Make from M10 x 1 5 bolt Screwdriver Slot to aid removal E 05824 Figure 5 1 Pilot Tool For Transmission To Engine Alignment Push the transmission toward the engine while guiding the pilot boss on the torque converter into the flexplate hub adapter or flywheel and the guide bolt into the hole on the flexplate a headless guide bolt in the engine flywheel housing may also aid in the transmission installation Seatthe transmission squarely against the engine flywheel housing no force is required If interference is encountered move the transmission away from the engine and investigate the cause Align the bolts holes in the converter housing with those in the engine flywheel housing Install all transmission to engine bolts and washers finger tight a minimum of 10 bolts is required and must include the top two CAUTION The entire converter housing circumference must be flush against the engine flywheel housing before tightening any bolts DO NOT use the bolts to seat the housing Tighten four bolts at equally spaced intervals around the converter housing bolt circle Use the torque specified by the engine or vehicle manufacturer Remove the flexplate guide bolt through the engine flywheel housing access opening Replace it with a self locking bolt Tighten the bolt finger tight 36 NOTE DO NOT tighten any
5. FULL THROTTLE 118 1 mm 4 65 in MOUNTING CLOSED THROTTLE LENGTH 95 2 mm 3 75 in NOTE Mounting length 50 8 mm 2 inches equals cable length 118 1 mm 4 65 in 95 2 mm 3 75 in The location of the clamping bracket relative to the fuel lever at closed throttle must be maintained within this range Attach to engine or governor 30 2 mm 1 19 in housing using clamp and shims as required Clamp must positively lock in cable groove HITCH PIN CLIP ENGINE FUEL LEVER 93 45 mm 3 679 in 87 15 mm 3431 in Fuel lever attachment linkage or bracket must allow fuel lever to return to closed throttle position when sensor rod is maintained at full throttle position Attach the throttle sensor directly to the engine fuel lever with no breakover or yield linkages between the engine fuel lever shaft and the attachment point of the throttle sensor CLOSED THROTTLE 183 1 mm 7 21 in MAX FULL THROTTLE SAME AS WITHOUT lt 160 2 mm 6 31 in MIN SLIP LINK Y gt FULLY EXTENDED EEE 38 1 mm 1 50 in m HITCH PIN CLIP FULLY RETRACTED OPTIONAL THROTTLE SENSOR ASSEMBLY WITH SLIP LINK V00430 06 Figure 4 4 Hitch Pin Throttle Position Sensor Installation Diagram 34 SECTION INSTALLING V TRANSMISSION INTO VEHICLE 9 1 HANDLING a Preventing Damage Carefully handle the transmission to prevent damage to com
6. NNY LOH 0E LOH V 670 670 E uggz 00 2 uggz 00 927 927 99ueJsIp SIU 10 99ueJsIp SIU 10 sauejd ul 68 seue d ul 68 2 686 6 86 eq 0 0 eqni 1 1 020 3NITH31N39 020 3NITH31N39 0 c NOISSIWSNY HL 0 9 NOISSIINSNY H L Figure 1 2 Fill Tube And Dipstick Requirements Shallow Oil Pan a Manual Fluid Check Procedure Clean all dirt from around the end 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 maintenance persons b 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 CAUTION The fluid level rises as fluid temperature increases DO NOT fill above the COLD CHECK band if the transmission fluid is below normal operating temperatures Park vehicles containing 1000 or 2200 models as follows Bring the vehicle to a complete stop on a level surface using the service brake Make sure that the engine is at low idle rpm Put the transmission
7. sensor damage 32 Fluid pressure gauge tubing damage kinks improper routing b Throttle Position Sensor TPS Adjustment When properly installed by the equipment manufacturer the TPS if used should not need adjustment If TPS adjustment is necessary confirm that it has been installed to ATD specification refer to Figure 4 4 The TPS is self calibrating and therefore has no optimum closed throttle or full throttle value Be sure there is no misalignment or obstruction to smooth movement through the full stroke of the TPS The Allison DOC for PC diagnostic tool can be used to check the TPS adjustment See the users manual that comes with the diagnostic tool for details Also be sure to check for diagnostic codes DTCs associated with TPS function c Hitch Pin Throttle Position Sensor Installation Install the throttle sensor body as follows Clamp cable end using clamp and shims refer to Figure 4 4 Secure the sensor body using the mounting holes provided Install a heat shield if any part of the throttle sensor is near the exhaust manifold turbochargers or any other heat source Adjust the throttle sensor as follows The engine fuel lever must be at the closed throttle position 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
8. If parking brake is present connect linkage FILLING HYDRAULIC SYSTEM Check that all unused hydraulic openings are plugged Hill the transmission with the required amount of Allison approved DEXRON III fluid refer to Paragraph 1 5 and 1 8 Run the engine for about one minute and check the fluid level refer to Paragraph 1 3 39 5 10 INSTALLATION CHECKLIST Use this list after transmission installation As items are checked mark them off this list Torque Values All oil pan bolts 24 29 N m 18 21 Ib ft Main pressure tap 10 13 N m 7 10 Ib ft Cooler fittings 0 750 16 inch series 20 30 N m 15 22 Ib ft 1 0625 12 inch series 34 47 N m 25 35 1b ft Cooler manifold bolts 20 34 15 25 Ib ft Flexplate adapter to converter cover bolts 57 68 N m 42 50 Ib ft Flexplate to crankshaft hub bolts Consult Engine Manufacturer Specifications Flexplate to flexplate adapter bolts 57 68 N m 42 50 Ib ft Fluid drain plug 30 40 N m 22 30 Ib ft Fluid fill tube bracket bolt Firmly seated against bracket Speed sensor bolts 10 13 N m 7 10 Ib ft Output flange bolt 108 136 N m 80 100 Ib ft cover bolts 51 61 N m 38 45 Ib ft PTO mounting bolts 51 61 N m 38 45 Ib ft switch to main housing 24 29 N m 18 21 Ib ft Selector lever nut customer supplied 20 27 N m 15 20 Ib ft PTO pressure
9. 3 4 3 2 3 3 3 4 3 5 SECTION IV 4 1 4 2 4 3 4 4 4 5 TABLE CONTENTS Description Page PREVENTIVE MAINTENANCE Periodic Inspections And 1 Importance Of Proper Transmission Fluid Level 3 Transmission Fluid 3 Keeping Fluid Clean 10 Fluid 10 Transmission Fluid And Filter Change Intervals 11 Transmission Fluid Contamination 13 Transmission Fluid And Filter Change Procedure 14 Oil Vent Breather 16 REMOVING TRANSMISSION Draining Transmission 17 Disconnecting Controls 17 Uncoupling From Driveline Engine And Vehicle 18 Removing The Transmission 18 Removing The Flexplate Adapter 19 Removing Output Flange Or Yoke 19 PREPARING THE TRANSMISSION FOR INSTALLATION Checking Input Components 20 Installing Output Flange Or Yoke 20 Installing PTO 22220 21 Installing Tube And 5 24 Checking Plugs And Openings 25 PREPARING VEHICLE FOR TRANSMISSION INSTALLATION Engine Transmission Adaptation Requirements 26 Checking Flexplate Drive Asse
10. 4 REMOVING THE TRANSMISSION CAUTION Do not pull the transmission away from the torque converter assembly The torque converter drive cover must be entirely free of any restraint by the flexplate drive or crankshaft pilot when the transmission separates from the engine WARNING Be sure the torque converter is moving rearward with the transmission as it is removed Do not allow the torque converter to become disengaged from the oil pump or to fall and injure yourself or others Move the transmission away from the engine approximately 34 6 mm 1 36 inch for a number 2 flywheel housing or 44 2 mm 1 74 inch for a number 3 flywheel housing until it is completely clear of the engine If used remove the adapter ring and or gasket Raise or lower the transmission as necessary to remove it from the vehicle 18 2 5 REMOVING THE FLEXPLATE ADAPTER Remove the flexplate adapter if present from the front of the torque converter This part will be needed for transfer if a replacement transmission is being installed WARNING Handle the transmission carefully whenever the torque converter retaining bracket is not present NEVER tilt the converter end down or the torque converter may slide forward disengaging the oil pump or may fall completely out of the transmission causing damage and or personal injury Attach a torque converter retaining bracket at the earliest opportunity The bracket keeps the torque converter from
11. and Maintenance Following an initial unit exchange program refer to the 1000 and 2000 Product Families Service Manual SM3191EN for detailed transmission service and maintenance instructions available late 1999 42 c Road Test Checklist Complete the following check list Neutral Start Circuit Starts only in N Neutral or P Park Instruments CHECK TRANS light Transmission fluid pressure gauge if used Speedometer Q Temperature gauge if used Reverse warning system if used Transmission Fluid L Fluid level meets specifications cold neutral level No leaks Warm up and check fluid level hot neutral level No Load Governed Engine Speed No load governed speed of engine Adjust governor as necessary refer to the manufacturer s specifications for the engine transmission being tested if installed C PTO operation Refer to the 1000 or 2000 vocational model specific operator s manual see Section VI for the latest publication number Shift Sequence U Transmission upshifts and downshifts smoothly through all ranges Other Checks Q Stall test must only be performed by qualified service technician Shift quality Comments 43 CUSTOMER SECTION SERVICE VI 6 1 OWNER ASSISTANCE There are distributors and dealers around the world ready to stand behind every Allison Transmission product Any situation that arises in con
12. flexplate to flexplate adapter bolts until J all of the bolts have been installed and tightened finger tight Rotate the engine crankshaft to install the remaining new adhesive coated bolts into the flexplate adapter After all bolts have been installed finger tight tighten the bolts to 57 68 N m 42 50 Ib ft Install the flywheel housing access cover if used 9 3 INSTALLING TRANSMISSION MOUNTING COMPONENTS CAUTION Use the type and grade of mounting bolts recommended y by the vehicle manufacturer Install all bolts washers spacer isolators or supports required to support the transmission in the vehicle frame Tighten the bolts to the torque values recommended by the vehicle manufacturer 9 4 COUPLING TO DRIVELINE Couple the driveline companion flange or universal joint yoke to the flange or yoke on the transmission Use the bolts and torque values recommended by the vehicle manufacturer Check the universal joint angularity of all U joints in the driveline Determine if they are within specification 5 5 CONNECTING POWER TAKEOFF CONTROLS If not already mounted mount the PTO s onto the transmission refer to Paragraph 14 3 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 Connect controls to the PTO Check for proper PTO control operation 37 CAUTION
13. indicator and mounting attachments base posts and clamps e 0 150 mm 0 6 inch depth micrometer b Flywheel Housing Pilot Bore Diameter The flywheel housing pilot bore diameter must measure e No 3 Housing 409 58 409 70 mm 16 125 16 130 inch e No 2 Housing 44768 44780 mm 17 625 17 630 inch c Flywheel Housing Bore Runout Flywheel housing bore runout cannot exceed 0 51 mm 0 020 inch TIR d Flywheel Housing Face Squareness The flywheel housing face cannot be out of square more than 0 51 mm 0 020 inch TIR e Crankshaft Hub Pilot or Adapter Diameter The crankshaft hub pilot or hub adapter pilot diameter must measure between 43 26 43 31 mm 1 703 1 705 inch f Crankshaft Hub Pilot or Adapter Squareness The crankshaft hub or hub adapter cannot be out of square more than 0 013 mm 0 0005 inch TIR per inch of diameter g 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 26 128 0 12 u 66120 60 10114 NIN u 001 0 dai 10114 ANH d3ldvav LIVHSYNVYO NO 10114 1 6961 7961 00705 56 6 ul 6071 6021 3NI1H31N39 9 LIVHSYNVHO n 3ONVHV319 NIN 66120 corp m 10 yooq BI 091 S JBS 620 98 Dueig 995 eouelea o 1900
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15. 14 CB e Hum ONISNOH NIV Z NOISSINSNVEL 5 1 HO JVS uv39 ONIY d3luvis Figure 4 3 Typical Arrangement Of Adaptation Components 29 h Flexplate Flatness Flexplate flatness must be 0 76 mm 0 030 inch TIR or less when measured at 292 mm 11 5 inch diameter i Torque Converter Axial Location This is controlled by the engine physical adaptation Using a depth gauge measure from the face of the engine flywheel housing to the face at the 292 1 mm 11 50 inch diameter The torque converter axial location should measure No 3 Housing 40 15 44 21 mm 1 581 1 741 inch e No 2 Housing 30 50 34 56 mm 1 201 1 361 inch 4 2 CHECKING FLEXPLATE DRIVE ASSEMBLY a Flexplate Inspection Check the flexplate for cracks distortion or elongated bolt holes Replace a worn or damaged flexplate b Engine Crankshaft End Play Make sure engine crankshaft end play is within the engine manufacturer s specifications NOTE When assembling the flexplate to the crankshaft hub or hub J adapter make sure the outer flexplate bolt holes are aligned c Flexplate Assembly Installation Install the flexplate onto the engine crankshaft hub using the bolts and torque values specified for that engine Refer to Figure 4 1 or 4 2 for the proper position of an installed flexplate 4 3 CHASSIS AND DRIVELINE INSPECTION Inspect the chassis and driveline components for the follow
16. 96067062 Nid 51010 ejeueo SL X S L X OLIN L 1108 uou eq sn Figure 4 1 1000 and 2000 Product Families Engine Adaptation No 3 Housing 27 22890 12 ur 6910 60 TO 10114 ANH 10114 NIN 0010 a d3ldVav LIVHSYNVYO NO 10114 C I ul 6961 7961 00705 56 6 071 607 1 3NI1H31N30 L Cb 97 t LIVHSYNVHO n 3ONVHV37O NIN 6G l0 go y 10 yooq ejeq 291 sejes ZZ0 r9SV ees 190010 0 paxo8uo aq 19 siu ejejdxelj 0061 6ullsix ueuM ur 0 021 Q061 V 10 Jey Speeoxe 9 5 5 uim JInsuo2 pasn siouejsej JI pomaria pinoys sjuawayinbay nbio peusiuunj pejejd uou urejd 104 senbio 69558 uolssiusue p l ddns jou 3Suejse Sued sejejdxe j 0 559228 10 eq 18 5310 ajqissiwued 007 ej do eui Buipnjoui s slloq 0 jo jaaymAY
17. E VEHICLE MANUFACTURER MUST first be thoroughly satisfied that neither personal safety nor equipment safety will be jeopardized by the service methods selected Proper service and repair is important to the safe reliable operation of the equipment The service procedures recommended by Allison Transmission or the vehicle manufacturer and described in this handbook are effective methods for performing service operations Some of these service operations require the use of tools specially designed for the purpose The special tools should be used when and as recommended Three types of headings are used in this manual to attract your attention These warnings and cautions advise of specific methods or actions that can result in personal injury damage to the equipment or cause the equipment to become unsafe WARNING A warning is used when an operating procedure practice etc if not correctly followed could result in personal injury or loss of life CAUTION caution is used when an operating procedure practice etc if not strictly observed could result in damage to or destruction of equipment NOTE A note is used when an operating procedure practice etc is J essential to highlight TRADEMARK INFORMATION DEXRON is a registered trademark of General Motors Corporation Allison DOC is a trademark of General Motors Corporation TranSynd is a trademark of Castrol Ltd Paragraph SECTION SECTION III
18. LNdN NOTES 1 1 PREVENTIVE SECTION MAINTENANCE I PERIODIC INSPECTIONS AND CARE Transmission Product Families Beginning January 2004 Allison Transmission began shipping new 1000 and 2000 Product Families vocation specific transmission models for North America 1000 and 2000 Product Families vocational models are Emergency Vehicle Series 1000 EVS 2100 EVS 2200 EVS 2500 EVS Highway Series 1000 HS 2100 HS 2200 HS 2500 HS Motorhome Series 1000 MH 2100 MH 2200 MH 2500 MH Pupil Transportation Shuttle Series 1000 PTS 2100 PTS 2200 PTS 2500 PTS Rugged Duty Series 1000 RDS 2100 RDS 2200 RDS 2500 RDS Specialty Series 1000 SP 2100 SP 2200 SP 2500 SP Bus Series B 210 B 220 The 1000 and 2000 Product Families include the 1000 2000 2400 Series transmissions Refer to WATCH 309 for detailed descriptions of the vocational models and their correlation to the existing 1000 2000 2400 Series Transmission Inspection CAUTION When cleaning the transmission do not spray steam water or cleaning solution directly at the breather oil vent Spraying steam water or cleaning solution at the breather can force the water or cleaning solution into the transmission and contaminate the transmission fluid Clean and inspect the exterior of the transmission at regular intervals Severity of service and operating conditions determine the frequency of these inspections Inspect t
19. Mechanic s Tips 1000 and 2000 Product Family Transmissions MT3190EN 2004 MARCH 01 MT3190EN Mechanic s Tips Allison Transmission VOCATIONAL MODELS 1000 EVS 2100 6 2200 EVS 2500 EVS 1000 HS 2100 HS 2200 HS 2500 HS 1000 2100 2200 MH 2500 1000 PTS 2100 2200 PTS 2500 PTS 1000RDS 2100 06 2200 RDS 2500 RDS 1000 SP 2100 SP 2200 SP 2500 SP B 210 B 220 1000 Series 2000 Series 2000 MH Series 2400 Series gt Allison Transmission Allison Transmission General Motors Corporation P O Box 894 Indianapolis Indiana 46202 0894 www allisontransmission com Printed in USA Copyright 2004 General Motors Corporation WARNINGS CAUTIONS AND NOTES IT IS YOUR RESPONSIBILITY to be completely familiar with the warnings and cautions described in this handbook It is however important to understand that these warnings and cautions are not exhaustive Allison Transmission could not possibly know evaluate and advise the service trade of all conceivable ways in which service might be done or of the possible hazardous consequences of each way The vehicle manufacturer is responsible for providing information related to the operation of vehicle systems including appropriate warnings cautions and notes Consequently Allison Transmission has not undertaken any such broad evaluation Accordingly ANYONE WHO USES A SERVICE PROCEDURE OR TOOL WHICH IS NOT RECOMMENDED BY ALLISON TRANSMISSION OR TH
20. N band d Consistency of Readings Always check the fluid level at least twice using the procedure described above Consistency repeatable readings is important to maintaining proper fluid level If inconsistent readings persist check the transmission breather to be sure it is clean and unclogged If readings are still inconsistent contact your nearest Allison distribution or dealer 1 4 KEEPING FLUID CLEAN Prevent foreign material from entering the transmission by using clean containers fillers etc Lay the dipstick in a clean place while filling the transmission CAUTION Containers or fillers that have been used for antifreeze solution or engine coolant must NEVER be used for transmission fluid Antifreeze and coolant solutions contain ethylene glycol which if put into the transmission can cause the clutch plates to fail 1 5 FLUID RECOMMENDATIONS Hydraulic fluids oils used in the transmission are important influences on transmission performance reliability and durability Only fluids meeting TES 295 TranSynd or DEXRONC III specifications are acceptable for use in the 1000 and 2000 Product Families transmissions To make sure the fluid is qualified for use in Allison transmissions check for a TES 295 or a DEXRON III fluid license or approval numbers on the container consult the lubricant manufacturer Consult your Allison Transmission dealer or distributor before using other fluid types result in tr
21. PTO units using transmission main pressure to engage the PTO gear must have a positive main pressure shut off at the solenoid valve when the PTO is not engaged Failure to provide this feature may cause inadvertent clutch apply and PTO damage 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 9 6 CONNECTING PARKING BRAKE CONTROL Connect and properly adjust the parking brake If present adjust the brake shoe to drum clearance as specified by the manufacturer 5 7 CONNECTING COOLER Figure 5 2 shows typical cooler port locations on the transmission Consult AS64 071 in Allison Sales Tech Data book for cooler fitting torque values MAIN PRESSURE TAP E TO COOLER PORT FROM COOLER PORT BOTTOM VIEW V05742 01 Figure 5 2 Cooler Port Location Remove the cover from the main transmission electrical connector and carefully connect the transmission external wiring harness Keep dirt and debris out of the connector 9 8 Connect the external wiring harness to the engine turbine and output speed sensors If used connect the PTO s connector s The PTO connector is NOT part of the Allison Transmission external wiring harness If used connect wire s to electric tachogra
22. TA 000 0 lt SOTA 000 0 lt SOTA 000 06 SOTA 000 SZ SOTA 000 SZ SOTA 000 SZ SPINA w pu amp sueAp uoN pue py pu Sugal JO 1n xIJAI YUM s eAa93ug duguO pue empeuos SUON pc SUON pc SUON p SUON pc SUON pc SUON pc uni 000 08 uni 000 08 000 091 wy 000 08 uni 000 08 000 08 S N 00008 S N 0000 lt 000001 S N 00008 S N 00008 S N 0000 lt lt 62 SAL w PUASULAL guguO pue sompoooud uosi py prepuejs uodn poseq ur suonepuoururooow pesn Jo 3uoored 00 Jo SULINSUD YM sorouojsrsuoour pue uonerra INP pozrugoooi Jo popuoeuruiooor jou Surgsn g e npeuos O 1921 puKguer uou pue PUASUeI Jo oJnjxiui urejuoo pue uoissiusueJ saiiure4 19npo4d 0002 0001 72 jeu suorssrmusue 104 pm pu Suei Jo 3uooJed QO Sururejuoo uorssrusuen ou uodn poseq IMPIS ur SUIMOT OJ OQ ALON pc pc pc SUON ZI ZI syUO ZI 000 08 000 08 000 08 000 000 000 S N 0000 lt S N 000 05 S N 0000 lt S N 000 SZ S N 000 SZ S N 000 S
23. Z S6Z SI L UoN pu amp SueA uoN 1 o3uem IMLA pue K1emmny oqnT puyum eu rojug 0005 SIA SIMMA NOLLVOOA NOLLVOOA 6 12 b Abnormal Conditions Transmissions used in high cycle rate applications should use fluid analysis to be certain that a proper fluid change interval is established Transmission fluid must be changed whenever there is evidence of dirt or a high temperature condition A high temperature condition is indicated by the transmission fluid being discolored or having a strong odor or by fluid analysis Local conditions severity of operation or duty cycle may require more or less frequent fluid or filter change intervals c Fluid Analysis Transmission protection and fluid change intervals can be optimized by monitoring fluid oxidation according to the tests and limits shown in Table 1 3 Consult your Distributor Dealer for an Oil Analysis Kit refer to SIL 17 TR 96 Rev A To be sure of consistent and accurate fluid analysis use only one fluid analysis firm Refer to the Technician s Guide for Automatic Transmission Fluid GN2055EN for additional information Table 1 3 Fluid Oxidation Measurement Limits Test Limit Viscosity 25 change from new fluid Total Acid Number 3 0 change from new fluid 1 7 TRANSMISSION FLUID CONTAMINATION a Fluid Exam
24. ansmission malfunction or reduced transmission life e CAUTION Disregarding minimum fluid temperature limits can When choosing the optimum viscosity grade of fluid to use duty cycle preheat capabilities and or geographical location must be taken into consideration Table 1 1 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 10 or PB Auto Apply Parking Brake if available or N Neutral for a minimum of 20 minutes before attempting range operation Table 1 1 Transmission Fluid Operating Temperature Requirements Ambient Temperature Below Which Preheat is Required Viscosity Grade Celsius Fahrenheit DEXRONGS III 27 17 TranSynd 33 22 Ref SIL 13 90 1 6 TRANSMISSION FLUID AND FILTER CHANGE INTERVALS CAUTION Transmission fluid and filter change frequency is determined by the severity of transmission service More frequent changes may be necessary than recommended in the general guidelines when operating conditions create high levels of contamination or overheating a Frequency Change the control main filter at or before the initial 8000 km 5000 miles then follow the schedule in Table 1 2 Table 1 2 is given only as general guide for fluid and filter change interval
25. clean and open b Maintenance The amount of dust and dirt encountered will determine the frequency of breather cleaning Use care when cleaning the transmission CAUTION When cleaning the transmission do not spray steam water or cleaning solution directly at the breather oil vent Spraying steam water or cleaning solution at the breather can force the water or cleaning solution into the transmission and contaminate the transmission fluid 16 SECTION REMOVING II TRANSMISSION 2 1 DRAINING TRANSMISSION Drain the transmission fluid before removing the transmission from the vehicle Remove the drain plug from the oil pan Examine the drained fluid for evidence of contamination refer to Paragraph 1 7 Reinstall the drain plug Remove the transmission fill tube if it interferes with transmission removal Plug the fill tube hole in the main housing to keep dirt from entering the transmission NOTE A significant amount of fluid may drain from the hydraulic J lines when they are disconnected from the transmission 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 2 2 DISCONNECTING CONTROLS Disconnect the external wiring harness from the main electrical connector three speed sensors and the NSBU switch refer to Pages viii and ix Prevent dirt or mois
26. e Refer to JA3664EN In Chassis Maintenance for replacement instructions If not replacing the oil seal lubricate it with high temperature grease or transmission fluid b Check Flange or Yoke CAUTION DO NOT attempt to polish the oil seal contact surface on the flange or yoke Scratches or machine type lead can cause the seal to leak Replace the output flange yoke if light scoring cannot be removed using crocus cloth 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 20 c Install Output Flange or Yoke CAUTION Be sure that the flange output shaft and retaining hardware are clean Care must be exercised to avoid transmission output seal or journal damage Check to be sure that the seal is free of tears and cuts Nicks and scratches must not exist on the lead in chamfer or seal journal section of the output flange or yoke Lubricate the splines of the output shaft and the oil seal assembly with transmission fluid or oil soluble grease CAUTION Do not use a hammer or other similar tool to force the Y flange yoke onto the shaft Forcing the flange yoke onto the shaft may result in transmission damage Start the yoke flange assembly onto the output shaft being sure that the splines are properly engaged and slide freely Push the yoke flange assembly into the rear c
27. e sure it is properly engaged Park vehicles containing 2100 or 2500 models with auto apply parking brakes as follows Bring the vehicle to a complete stop on a level surface using the service brake Make sure that the engine is at low idle rpm Put the transmission in PB Auto Apply Parking Brake Make sure that the parking brake is properly engaged Apply the emergency brake if present and make sure it is properly engaged Park vehicles containing 2100 or 2500 models without auto apply parking brakes as follows Bring the vehicle to a complete stop on a level surface using the service brake Make sure that the engine is at low idle rpm Put the transmission in N Neutral Apply the emergency brake and or parking brake and make sure they are properly engaged Chock the wheels and take any other steps necessary to keep the vehicle from moving With the engine running remove the dipstick from the tube and wipe the dipstick clean nsert the dipstick into the tube and remove Check fluid level reading Repeat the check procedure to verify the reading dipstick See Figures 1 1 and The width of the HOT RUN band represents approximately 1 0 liter 1 06 quart of fluid at normal operating sump temperature 4 NOTE Safe operating level is within the HOT RUN band on the Ifthe fluid level is not within the HOT RUN band add or drain as necessary to bring the fluid level to within the HOT RU
28. e transmission service manual and electronic controls troubleshooting manual Unless specifically indicated otherwise this handbook refers to all 1000 and 2000 Product Families transmissions The differences between the various transmissions are explained as required l3VHS SNIGHNL HOLNTD 9 HOLNTD 9 d3lild NIVIN TOHLNOO 20720505 0 HV39 Old HO Old ON 51 T33HM 3NO1 NOLLONS JINGOW 21112 ONILVLOY wc JINON 3A1VA TOH1INOO NVd 110 AHdV13NV1d 1 AdV13NV1d d ANO 0022 0001 IMWd AdVL3NV ld d LAVHS 1 41 0 YOSNAS 03345 11110 H3A09 uva 31ndON Y43409 uV3H ES HOSN3S fiuoddns 1NOH4 HOLNTO 9 10 HOSN3S 43385 1 4 ONISNOH ONISNOH ONISNOH JINGOW LYOddNS 1 9 5 H31H3ANOO NOILO3S 55045 Sli vd 0002 0001 3304 1nd1nO LAVHS NIYIN 1 19 99 H91019 v2 1 8 355 3183ANOO 310801 vi 2020612801 NVd MOTIVHS d3A09 8738
29. est edition of the 1000 and 2000 Product instructions Refer to Section VI for the latest publication number a Driveability Drive away checks are performed to verify proper transmission and support equipment installation and operation The following steps outline drive away check procedures e Check Fluid fill the transmission with appropriate fluid Start the Vehicle check for proper system response during start up Turn on the vehicle s master ignition switch The CHECK TRANS light should come on Start the engine The CHECK TRANS light should go off Clear Trouble Codes during installation it is common for false codes to be stored in the electronic control s TCM These codes must be cleared prior to road testing the vehicle Refer to Allison DOC users manual for details e Road Test the Vehicle allow the electronic control time to converge shifts Check for Proper Operation check all components for proper mounting and operation and check for transmission fluid leaks at gasket surfaces lines and hoses Re check for Trouble Codes use the Allison DOC diagnostic tool to determine if codes were set during the road test See Allison DOC users manual for details Troubleshoot if codes exist after the road test problems must be found and corrected Refer to TS3192EN 1000 and 2000 Product Families Electronic Troubleshooting Manual b Service
30. fill tube bolt and tighten until it is firmly seated against the bracket 24 3 5 CHECKING PLUGS AND OPENINGS Carefully check all sides and the bottom of the transmission for loose or missing plugs Main Pressure Tap Plug Check that 0 4375 20 UNF 2A pressure plug is tightened to 10 13 N m 7 10 Ib ft b Fluid Drain Plug Check that the drain plug is tightened to 25 32 N m 18 24 Ib ft c Tachograph Plug If present tighten to 60 67 N m 4449 Ib ft d Cleanliness Check the openings into which the cooler lines connect for defor mities or obstructions Check the transmission electrical connectors for cleanliness Clean electrical connections with an LPS cleaner only refer to Service Information Letter 17 TR 94 25 PREPARING VEHICLE Trot FOR TRANSMISSION IV O O 0 INSTALLATION 4 1 ENGINE IRANSMISSION ADAPTATION REQUIREMIENTS You must make sure a new transmission installation can be adapted to the vehicle s engine Using the measurements described in this section assures correct transmission to engine adaptation Refer to or installation drawings AS64 022 and or AS64 023 in the Allison Sales Tech Data book Typical arrangement of adaptation components is shown in Figure 4 3 a Measuring Equipment The following measuring equipment is required 600 mm 24 inch precision caliper 50 100 mm 2 4 inch telescoping gauge e 25 76 mm 1 3 inch outside micrometer Dial
31. 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 Ib ft Tighten nuts to manufacturers specifications Be sure that the PTO backlash meets manufacturers requirements d Connect PTO Lube if required Some PTOs require pressure lubrication When needed tap into the cooler return fitting or line at the transmission converter housing see Figure 3 1 An orifice of 0 81 mm 0 031 inch must be present in the line to control the amount of fluid diverted from the transmission Some PTO assem blies contain internal restrictions equivalent to the required orifice check 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 See Figure 3 2 which shows this connection schematically MAIN PRESSURE TAP TO COOLER PORT FROM COOLER PORT BOTTOM VIEW V05742 01 Figure 3 1 Cooler Port and Main Pressure Tap Location 22 FROM COOLER PORT PTO LUBE LINE with 0 81 mm 0 032 in orifice COOLER RETURN OIL LINE ENLARGED DETAIL 05816 Figure 3 2 Lube Plumbing Schematic e Connect PTO Clutch Feed if required Some PTOs are clutch a
32. he transmission for loose bolts transmission and mounting components e leaks repair immediately loose dirty or improperly adjusted throttle sensor or shift selector linkage damaged or loose hoses worn frayed or improperly routed electrical harnesses worn or frayed electrical connections worn or out of phase driveline U joints and slip fittings clogged or dirty oil vent breather Vehicle Inspection Check the vehicle cooling system occasionally for evidence of transmission fluid which would indicate a faulty oil cooler Welding CAUTION When welding on the vehicle DO NOT WELD on the vehicle without disconnecting from the TCM all control system wiring harness connectors DO NOT WELD on the vehicle without disconnecting TCM battery power and ground leads DO NOT WELD on any control components DO NOT CONNECT welding cables to any control components A label describing on vehicle welding precautions is available from your authorized Allison service dealer and should be installed in a conspicuous place A vehicle used in a vocation that requires frequent modifications or repairs involving welding must have an on vehicle welding label 5 2607 1 2 IMPORTANCE OF PROPER TRANSMISSION FLUID LEVEL Transmission fluid cools lubricates and transmits hydraulic power Always maintain proper fluid level If fluid level is too low the torque converter and clutches do not receive an adequate
33. hose to transmission 10 13 N m 7 10 Ib ft Rear cover bolts 51 61 N m 38 45 Ib ft TPS to engine bracket M6 bolts 10 13 7 10 Ib ft 0 250 20 bolts 12 15 N m 9 11 Ib 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 40 Driveline for Proper indexing of universal joints Proper drive shaft angles Driveline backlash Lubricated universals and slip joints Hydraulic System for Recommended fluid TranSynd Correct fluid level in transmission Dipstick correctly calibrated refer to Figure 1 1 Fill tube tight Fill tube cap tight Breather clean and free of restrictions No leaks during operation Instruments and Electrical Equipment for Proper wiring and electrical connections Instruments gauges and lights work correctly U Shift selector display is 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 41 5 11 ROAD TEST AND VEHICLE OPERATION CHECKLIST Families transmission Operator s Handbook for operating 4 NOTE Refer to the lat
34. in P Park Engage the P Park range by slowly releasing the service brake Apply the emergency brake and or parking brake if present and make sure it is properly engaged Park vehicles containing 2100 or 2500 models with auto apply parking brakes as follows Bring the vehicle to a complete stop on a level surface using the service brake Make sure that the engine is at low idle rpm Put the transmission in PB Auto Apply Parking Brake Make sure that the parking brake is properly engaged Apply the emergency brake if present and make sure it is properly engaged Park vehicles containing 2100 or 2500 models without auto apply parking brakes as follows Bring the vehicle to a complete stop on a level surface using the service brake Make sure that the engine is at low idle rpm Put the transmission in N Neutral Apply the emergency brake and or parking brake and make sure they are properly engaged Chock the wheels and take any other steps necessary to keep the vehicle from moving 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 Auto Apply Parking Brake if available or N Neutral and allow the engine to idle 500 800 rpm Slowly release the service brakes With the engine running remove the dipstick from the tube and wipe the dipstick c
35. ination At each fluid change examine the drained fluid for evidence of dirt or water A normal amount of condensation will appear in the fluid during operation b Water Obvious water contamination of the transmission fluid or transmission fluid in the heat exchanger coolant indicates a leak between the water and fluid areas of the cooler Inspect and pressure test the cooler to confirm the leak Replace leaking coolers NOTE Coolant can also be contaminated by engine oil be sure to locate the correct source of coolant contamination c Engine Coolant CAUTION Engine coolant in the transmission hydraulic system requires immediate action to prevent malfunction and possible serious damage Completely disassemble inspect and clean the transmission Remove all traces of the coolant and varnish deposits resulting from engine coolant contamination Refer to SIL 18 TR 98 for more information d 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 CAUTION After flushing the cooler with Kwik Flush Cart J 46550 be sure to check the external cooler c
36. ing conditions and correct them as appropriate Transmission mounts broken or worn out Bolts and other hardware damaged missing or incorrect Isolators rubber mounts damaged or missing Driveline angles runout or balance which does not conform to the manufacturer s recommendations Driveline yoke slip joints freedom of movement damaged or worn out correctly lubricated correctly indexed 30 Driveline midship or hanger bearings damaged or misaligned Universal joints freedom of movement damaged or worn out correctly lubricated correctly indexed Vehicle differential backlash manufacturer s specification Universal joint coupling alignment and differential damage Cross frame members and rear support members condition and location PTO driven equipment shafts and couplings damaged or misaligned Auxiliary transmission shaft alignment alignment of yoke or flange backlash fluid leaks 4 4 COOLER FILTER AND LINES a Inspection 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 Clean and flush transmission fluid cooler both coolant and oil sides Pressure check both sides using a 276 kPa 40 psi air supply Hydraulic line
37. ircuit restriction If circuit pressure drop is above specification the cooler has excessive trapped particles and must be replaced 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 AS64 071 or AS 64 072 in the Allison Sales Tech Data book 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 4 NOTE When equipment to flush the oil cooler is not available install 1 8 TRANSMISSION FLUID AND FILTER CHANGE PROCEDURE a Drain Fluid NOTE Do not drain the transmission fluid if changing the control J main filter only Drain the fluid when the transmission is at normal operating sump temperature 71 C 93 C 160 F 200 F Hot fluid flows quicker and drains more completely Remove the drain plug from the oil pan and allow the fluid to drain into a suitable container Examine the fluid as described in Paragraph 1 7 b Replace Control Main Filter Figure 1 3 1 Using J 45023 filter wrench or a strap filter wrench remove the control main filter by rotating it in the counterclockwise direction Use a standard strap type filter wrench 1705805 Figure 1 3 2 Remove the magnet from the filter attachment tube o
38. it is properly engaged 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 WARNING For vehicles containing 2100 or 2500 models without auto apply parking brakes each time you park the vehicle or leave the operator s station with the engine running do the following Bring the vehicle to a complete stop using the service brake Make sure that the engine is at low idle rpm Put the transmission in N Neutral Apply the emergency brake and or parking brake and make sure they are properly engaged 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 that the fill tube and dipstick meet Allison Transmission specifications Requirements for the standard oil pan are shown in Figure 1 1 and requirements for the shallow oil pan are shown in Figure 1 2 When checking a long dipstick calibration Besure the dipstick contacts the oil pan surface as shown in Take measurements from the end of the dipstick When checking a short dipstick calibration Remove the oil pan Take meas
39. lean Insert the dipstick into the tube and remove Check the fluid level reading Repeat the check procedure to verify the reading 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 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 Hot Check Procedure CAUTION The fluid must be hot to provide an accurate check The Y fluid level rises as temperature increases e Operate the transmission in D Drive range until normal operating temperature is reached sump temperature 71 C 93 C 160 F 200 F converter out temperature 82 C 104 C 180 F 220 F If a transmission temperature gauge is not present check fluid level when the engine water temperature gauge has stabilized and the transmission has been operated under load for at least one hour Park vehicles containing 1000 or 2200 models as follows Bring the vehicle to a complete stop on a level surface using the service brake Make sure that the engine is at low idle rpm Put the transmission in P Park Engage the P Park range by slowly releasing the service brake Apply the emergency brake and or parking brake if present and mak
40. mbly 30 Chassis And Driveline Inspection 30 Cooler Filter And 31 Checking Controls 32 iii Paragraph SECTION V 0 1 SECTION VI 6 1 6 2 Description INSTALLING TRANSMISSION INTO VEHICLE Handling SE Mounting To Engine Installing Transmission Mounting Components Coupling To Connecting Power Takeoff Controls Connecting Parking Brake Control Connecting Connecting Controls Filling Hydraulic System Installation Checklist Road Test And Vehicle Operation Checklist CUSTOMER SERVICE Owner Assistance Service 44 44 PREFACE This handbook is a mechanic s reference for maintaining removing or installing 1000 and 2000 Product Families transmissions All features of the transmission and the vehicle involved in installation procedures are discussed The information presented will help the mechanic maintain remove or install the transmission in a manner that assures satisfactory operation and long service life For additional detailed information refer to the appropriat
41. nection with the sale operation or service of your transmission will be handled by the distributor or dealer in your area Technical support is available from the Technical Assistance Center TAC by telephone at 1 800 252 5283 Refer to the Allison Transmission website www allisontransmission com or to the Worldwide Sales and Service Directory SA2229EN for a current listing of Allison Transmission authorized distributors and service dealers 6 2 SERVICE LITERATURE This service literature provides fully illustrated instructions for operation maintenance service overhaul and parts support for your transmission For maximum performance and service life from your unit see your dealer or distributor for the following publications Check the telephone directory for the Allison Transmission service outlet nearest you Table 6 1 1000 and 2000 Product Families Service Literature Service Manual SM3191EN Parts Catalog PC3062EN CD3062EN Electronic Troubleshooting Manual TS3192EN Principles of Operation PO3065EN EVS Operator s Manual OM3761EN HS Operator s Manual OM3757EN RDS Operator s Manual OM3759EN MHS Operator s Manual OM3364EN PTS Operator s Manual OM3758EN BUS Operator s Manual OM3765EN In Chassis Maintenance JA3664EN 1000 2000 2400 Operator s Manual OM3063EN Also Available On The Internet At www allisontransmission com NOTES 45 NOTES 46
42. over module Install a new output shaft sealing washer and the output shaft bolt CAUTION Use of an impact wrench requires the retention of the Y yoke flange to prevent internal transmission damage Tighten the output shaft bolt to 110 135 N m 80 100 Ib ft Rotate the yoke flange assembly by hand to check for binding interference and runout 3 3 INSTALLING PTO Access to the PTO mounting pads and the space available to maneuver the transmission determine whether the PTO should be installed before or after the transmission is installed CAUTION DO NOT use cork or other soft gaskets to install the PTO Use only the shims gaskets listed in the 1000 and 2000 Product Families Tech Data Book NOTE DO NOT use sealing compounds they are usually J incompatible with automatic transmission fluid 21 a Install Guide Pins included in the PTO manufacturers 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 converter housing PTO pad Tighten the pins b Install Gasket Install the special gasket over the guide pins ribbed surface away from the transmission c Mount the PTO CAUTION M10 bolts MUST be used to attach the PTO to the transmission Inch series threads 375 16 UNC will damage the transmission main housing Mount the PTO on the guide pins or studs provided in PTO kit Mesh the PTO driven
43. ph Make sure the speed sensors the PTO connector and all other connectors are securely seated and latched A connector can be heard or felt to latch but confirm the latching by pulling on the connector NOT THE WIRES The transmission has a sump fluid thermistor on the pressure switch manifold Actual temperature readings may be made using the PC based diagnostic tool Consult the users manual furnished with the Allison DOC diagnostic tool A temperature gauge may be installed in the To Cooler line If equipped for them install a temperature probe capillary tube and bulb or a thermocouple If equipped with a capillary tube and bulb Tighten the adapter tight enough to prevent leakage Install the bulb into the adapter and tighten the nut Check the capillary tube for interference with other parts that might chafe or damage the tube Long tubes may require support clips or brackets If equipped with a thermocouple Install the thermocouple and connect the leads CONNECTING CONTROLS Remove any protective covering from the wiring harness connectors Connect the external wiring harness to the main electrical connector the three speed sensors and the NSBU switch refer to Pages viii and ix Connect linkage to the transmission shift lever For information on adjusting the NSBU switch or the shift linkage see JA3664EN In Chassis Maintenance If PTO s is are used connect the PTO s wiring harness es
44. ponents in the installation path b Control of Transmission Movements Use a hoist or transmission jack that allows precise control of transmission movements during installation 9 2 MOUNTING TO ENGINE Use the following procedure to mount the transmission to the engine WARNING Handle the transmission carefully whenever the torque converter retaining bracket is not present NEVER tilt the converter end down or the torque converter may slide forward disengaging the oil pump or may fall completely out of the transmission causing damage and or personal injury Inspect the flexplate adapter if used for cracks or other damage and replace it when these conditions found Remove the torque converter retaining bracket just before the transmission is ready to be installed in the vehicle Attach the flexplate adapter to the front of the torque converter or to the flexplate using six new adhesive coated M10 x 1 5 x 15 bolts Tighten each bolt to 57 68 N m 42 50 Ib ft Align one of the flexplate s bolt holes with the access opening in the engine flywheel housing Lubricate the center pilot boss with molybdenum disulfide grease Molycote G or equivalent 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 see Figure 5 1 Align the guide bolt with the flexplate hole at the access opening 35 FLYWHEEL HOUSING
45. pplied Use transmission main pressure from the main pressure tap for applying the PTO clutch See Figure 3 1 for the location of the main pressure tap and Figure 3 3 for a typical plumbing schematic when this feature is needed This connection can be made later if the clutch apply line will interfere with transmission installation 23 EXHAUST TO TRANSMISSION THROUGH PTO TRANSMISSION MAIN PRESSURE MANUAL HYDRAULIC D VALVE OR SOLENOID VALVE FROM COOLER PORT PTO LUBE LINE with 0 81 mm 0 032 in orifice V05817 Figure 3 3 PTO Clutch Pressure Plumbing Schematic 3 4 INSTALLING FILL TUBE AND SEAL a Location The fill tube may be mounted on either the right or left side The unused fill tube provision must have a plug in the fill tube opening CAUTION Install a fill tube bracket using the correct length M8 Y self tapping 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 AS64 065 in the Allison Sales Tech Data book for the correct screw specifications b Installation If the fill tube will interfere with the installation of the transmission delay this step until after the transmission is in the vehicle Install the fill tube seal into the main housing Insert the fill tube through the seal until the shoulder at the bottom of the fill tube contacts the seal Align the tube bracket with its bolt location Install the
46. r from the top of the filter element 3 Clean any metal debris from the magnet Report any metal pieces larger than dust to your maintenance personnel 4 Reinstall the magnet onto the filter attachment tube Lubricate the gasket on the control main filter with transmission fluid 6 Install by hand the control main filter until the gasket on the control main filter touches the converter housing or cooler manifold CAUTION Turning the control main filter more than ONE FULL Y 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 Ib ft c Refill Transmission 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 Paragraph 1 3 Table 1 4 Transmission Fluid Capacity Initial Fill Refill Sump Liters Quarts Liters Quarts Standard 14 14 8 10 10 6 Shallow 12 12 7 7 74 Approximate quantities do not include external lines and cooler hose 1 9 OIL VENT BREATHER a Location and Purpose The breather is located at the top left rear of the transmission main housing The breather prevents air pressure buildup within the transmission and its passage must be kept
47. s Check for contamination clean and flush as necessary Inspect for deterioration Inspect for faulty connectors or kinks 31 b After Overhaul A complete cleanup of the transmission system after an over haul cannot be assumed See JA3664EN In Chassis Maintenance for cooler flush ing procedure 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 AS64 071 or AS 64 072 in the Allison Sales Tech Data book 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 4 NOTE When equipment to flush the cooler is not available install 4 5 CHECKING CONTROLS a Inspection Inspect the following and correct any faulty conditions Shift selector improper operation improper cable routing Cab and chassis wiring harness poor connections frayed insulation wiring damage 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
48. sliding out of engagement with the oil pump or from falling off completely and being damaged or causing personal injury 2 6 REMOVING OUTPUT FLANGE OR YOKE If replacing the transmission you may need to transfer the output flange or yoke to the replacement transmission The output flange or yoke is retained by one 1 20 x 234 inch flanged head bolt PREPARING THE TRANSMISSION FOR III INSTALLATION SECTION 3 1 CHECKING INPUT COMPONENTS a 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 b Pilot Boss Check the pilot boss at the center of the torque converter for damage or raised metal that prevents free entry into the crankshaft hub or adapter c Starter Ring Gear Check the starter ring gear for excessive wear or damage d Transmission Mounting Flange Check the transmission mounting flange for raised metal dirt or if used pieces of gasket material e Transmission to Engine Mounting Flange Inspect the transmission to engine mounting flange for raised metal burrs or pieces of gasket material if used Remove any of these defects Inspect the threaded holes for damaged threads 3 2 INSTALLING OUTPUT FLANGE OR YOKE a Output Oil Seal Check the output oil seal for leaks or damag
49. supply of fluid and the transmission overheats If the level is too high the fluid aerates causing the transmission to shift erratically and overheat Fluid may be expelled through the breather or dipstick tube when the fluid level is too high 1 3 TRANSMISSION FLUID CHECK WARNING For vehicles containing 1000 or 2200 models each time you park the vehicle or leave the operator s station with the engine running do the following Bring the vehicle to a complete stop using the service brake Make sure that the engine is at low idle rpm Put the transmission in P Park Engage the P Park range by slowly releasing the service brake Apply the emergency brake and or parking brake if present and make sure it is properly engaged 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 WARNING For vehicles containing 2100 or 2500 models with auto apply parking brakes each time you park the vehicle or leave the operator s station with the engine running do the following Bring the vehicle to a complete stop using the service brake Make sure that the engine is at low idle rpm Put the transmission in PB Auto Apply Parking Brake Make sure that the parking brake is properly engaged Apply the emergency brake if present and make sure
50. the cable end is pulled an additional 15 22 9 mm 0 60 0 90 inch from the idle position Recheck the stroke distance of the throttle sensor from closed to wide open after installation is completed Stroke distance must be from 15 2 22 9 mm 0 60 0 90 inch Recheck for zero clearance at the fuel lever Make sure that the 15 2 22 9 mm 0 60 0 90 inch dimension has not changed Design throttle sensor linkage brackets and levers to nominal dimensions so that the system stays within tolerance bands throughout its operating life 33 BENDING LOAD APPLIED MOUNTING PROVISION Use M6 x 1 00 or 14 20 in series bolts 3 places Torque M6 x 1 00 bolt to 10 13 Nem 84 120 Ib in Torque 74 20 in series bolts to 13 14 Nem 108 132 Ib in Mount to a solid frame member Flatness of chassis mounting surface must not exceed 0 8 mm 0 03 in UNACCEPTABLE INSTALLATION 10 09 MAX INSTALLED OPERATING ANGLE IN ALL DIRECTIONS LOADING IN TENSION ONLY ACCEPTABLE INSTALLATION Attachment must provide freedom of motion to allow cable loading in tension only no bending loads WIRING HARNESS 55 0 mm 2 17 in MIN REQUIRED Fuel control must not move FOR CONNECTION the throttle sensor beyond the closed throttle position at any time R 152 0 mm 6 00 in MIN REMOVAL ALLOWANCE RADIUS FULLY EXTENDED FORCE REQUIRED 26 7 N 6 0 LB MAX FULLY RETRACTED 47 5 mm 1 87 in
51. ture from entering a disconnected connector Position the wiring harness so it does not interfere with transmission removal Disconnect linkage from the customer furnished transmission shift lever Position the disconnected linkage so it does not interfere with transmission removal Leave the shift lever and NSBU switch on the transmission e If PTO s is are used disconnect the PTO s wiring harness es If parking brake is present disconnect linkage 2 3 UNCOUPLING FROM DRIVELINE ENGINE AND VEHICLE WARNING Chock wheels to prevent vehicle from moving when driveline is disconnected This is not necessary if vehicle is on a lift or jackstands Disconnect the vehicle drive shaft from the transmission output flange or yoke Position the disconnected shaft to avoid interference when removing the transmission If PTO equipped disconnect PTO connections such as PTO hydraulic hoses PTO powered equipment drive shaft If transmission mountings support the rear of the engine place a jack or other support under the engine Securely support the transmission with a hoist jack or other suitable removal equipment Remove all bolts nuts washers spacers and supports that attach the transmission to the vehicle and the engine access cover to remove flexplate or flexplate adapter bolts This is the 4 NOTE It may be necessary to remove an engine flywheel housing engine to transmission connection 2
52. urements from the oil pan splitline 08S0A MOILSdIGd 3801 11134 LHOHS yoiisdip JO pue SJUBWAINSBAW YOY MOILSdIG 38fiL 11154 SNOT ued io 198 uo5 Isnui xonsdiq ut 10 6 10 anva 0102 0102 Y WOIdAL 7 WOIdAL Ajuo i 1185 NVd 11 11 Y uns ied 10 0 6 70 660 3 uggz 070i uggz 070i 9z Y 9 eouejsip SIU 10 eouejsip SIU 10 seue d e a ul 66 seuejd jedan ul 66 u 686 5 6 86 o1 eqni 14 0 eqni 114 _ _ C 020 3NI1H31N32 ut 020 3NITH31N39 0 s NOISSIINSNVHL 0 NOISSIASNVHL VoM Figure 1 1 Fill Tube And Dipstick Requirements Standard Oil Pan 70840 MdILSdiId 38fiL 11154 LHOHS JO pue SJUBWAINSBAWW y09UO MOILSdIG 38fiL 11154 SNOT ued io 92u09 1snui xonsdiq 9 G 88 aNva 1 4102 Y X93H9 102 WOIdAL JJ Y WOIdAL I 1 INN iag 3NI1 Las NVd 11 1l Y t At
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