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Mechanic`s Tips MD/HD/B Series Allison On

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1. 1ejeureip 5821 026 9 7331 Figure 5 1 MD B 300 B 400 Engine Adaptation apisino eys 6961 9 60 epo o ur 6661 go F ggg 3 WOIdAL 41412 099 ualdvav 31V1dX314 6022 1 670 pez uregzz Stag SIO Ta3HMAH ur pzez e 3NI9N3 40 3284 ur pzez 699 geug P I 118096 9126 001002 10 14 81 59 9 88 54 01 ase sped epis UOISSIUISUEJ pesn jou ale sped epis UOISSIUISUEA SLiNaW3auHinoO3H NOLLVLdVGV WIVIO 39VdS NOISSIINSNVYL A 096 9616 SNH 1 NO 10114 3 14343 L3VHSNNVHO 79101 11810 00 lt gt WAWIXWW 0070 ww 90072 NIN 6 00 002 gt lt LJVHSXNVHO NO HOLVOIONI 19101 0262 0099 W
2. ADJUST SO TOTAL STROKE IS WITHIN 0 COUNT 50 200 COUNT BAND 255 COUNTS 14 COUNTS 233 COUNTS ERROR 1 ZONE 150 COUNTS 200 COUNTS ZONE APPROX 19 mm 0 75 in STROKE CLOSED WIDE OPEN THROTTLE THROTTLE p EE AT REST TOTAL STROKE CT WOT 15 2 mm 22 9 mm 42 n 0 6 in 0 9 in du 0mm 85 130 Counts 45 7 mm 1 8 in V00429 01 00 Figure 5 6 Throttle Position Determination Diagram e Adjust the throttle sensor as follows 1 The engine fuel lever must be at the closed throttle position 2 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 15 2 22 9 mm 0 60 0 90 inch from the idle position 3 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 4 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 5 Design throttle sensor linkage brackets and levers to nominal dimensions so the system stays within tolerance bands throughout its operating life 67 INSTALLING Section TRANSMISSION INTO VEHICLE 6 1 HANDLING a Preventing Damage Carefully handle the transmission to prevent damage to components in the instal
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4. NOTE Whenever a transmission has been overhauled exchanged or undergone internal repairs the ECU must be Reset to Unadapted Shift 3 Clear Trouble Codes During installation it is common for false codes to be stored in the ECU These codes must be cleared prior to road testing the vehicle 4 Road Test the Vehicle Allow the electronic control time to converge shifts 5 Check for Proper Operation Check all components for proper mounting and operation e Check for transmission fluid leaks at gasket surfaces lines and hoses 76 6 Recheck for Trouble Codes e Use the Allison DOC For PC diagnostic tool or shift selector to determine if codes were set during the road test e Refer to Section 2 11 Troubleshooting Paragraph Clearing Trouble Codes Using Shift Selector and Paragraph d Retrieving Troubleshooting Codes 7 Troubleshoot If codes exist after the road test problems must be found and corrected Refer to Allison Transmission publication number TS2470EN MD HD B Series WTECI Electronic Controls Troubleshooting Manual Service and Maintenance Refer to Allison Transmission publication number SM2148EN MD B 300 B 400 Series On Highway Service Manual for detailed transmission service and maintenance instructions Refer to Allison Transmission publication number SM2457EN HD 4000 B 500 Series Automatic Service Manual for detailed transmission service and maintenance i
5. CRANKSHAFT HUB ADAPTER STARTER RING GEAR WEARPLATE FLEXPLATE ASSEMBLY FLEXPLATE ADAPTER V00533 01 00 Figure 5 4 Arrangement of Adaptation Components c Flexplate Assembly Installation NOTE Be sure the outer flexplate bolt holes are aligned when assembling the flexplate to the crankshaft hub or hub adapter Install the flexplate onto the engine crankshaft hub using the bolts and torque values specified for that engine Refer to Figure 5 1 MD B 300 B 400 Series transmissions or Figure 5 2 HD B 500 Series transmissions for engine adaptation requirements Refer to Figure 5 4 for the proper position of the flexplate in relation to other adaptation components 5 3 CHASSIS AND DRIVELINE INSPECTION Inspect the chassis and driveline components for the following 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 62 5 4 Driveline yoke slip joints Freedom of movement Damaged or worn out Correctly lubricated Correctly indexed Driveline midship or hanger bearings damaged or misaligned Universal joints Freedom of movement Damaged or worn out Correctly lubricated Correctly indexed Vehicle differential backlash m
6. uri 000 08 uni 000 08 unt 000 08 000 06 SAMIN 000706 SOLIN 0007061 SIH 000 06 000706 000 0 lt 6F0FS6Z N d PM Seambey IMPON 01005 c 6 SH L x PuAsueip ig IMPAS smoH 000 smoH 0006 0007 0006 smoH 0006 smoH 0006 SUON 96 SUMO 9 gp oc mega SHUI 96 000 021 000 021 ui 000 OFZ 000 021 000 021 000 021 000 5 SIN 000 SIIN 000 OST SN 000 SL SIN 000 SL s ININ 000 6 0 lt 62 N d 1DI JIA soxmbosp IMPON 0 5000 1 4 c c SH L x PuASue1 7 smoH 0001 smoH 0001 smoH 0001 006 smoH 00 006 SUON ZI 09 B ZI CN aaa ND 9 000 OF 000 Or 000 09 000 00 uni 000 00 unt 000 00 S N 000 lt 2 SAMIN 00052 SAHN 000762 000 1 SAMIN 000 21 SALIN 000721 C67 SH L UON x Pu Sue1 UON IMPAS eu rojug euU 401 9 SS ae SSNOLLVOOA NOLLVOOA 5 01551 005 404 4 7 2 28 b Abnormal Conditions Transmission fluid must be changed whenever there is evidence of dirt or high
7. PTO PROVISION SPEED SENSOR OUTPUT SPEED 5 SENSOR X FEEDTHROUGH HARNESS 54 S CONNECTOR COOLER PORTS NAMEPLATE O NOTE Inch Series Threads 1 MAIN PRESSURE NOTE Inch Series Threads MD B 300P B 400P RIGHT REAR VIEW BREATHER FEEDTHROUGH HARNESS CONNECTOR TORQUE CONVERTER WITH LOCKUP CLUTCH AND TORSIONAL DAMPER ASSEMBLY PADS BOTH SIDES MAIN PRESSURE FLEXPLATE NOTE Inch Series Threads DRIVE SHOWN PTO PROVISION WITH STARTER RING Goan AVAILABLE BOTH SIDES MD B 300P B 400P LEFT FRONT VIEW 07790 01 00 13 BREATHER ASSEMBLY PADS 5 X GS k INPUT SPEED SENSOR NAMEPLATE ELECTRICAL HARNESS TIE DOWN BRACKET MAIN PRESSURE TAP NOTE Inch Series Threads NOTE Inch Series Threads TRANSMISSION ELECTRICAL CONNECTOR MD B 300R B 400R RIGHT REAR VIEW ASSEMBLY PADS BOTH SIDES BREATHER gt TORQUE CONVERTER WITH LOCKUP CLUTCH AND TORSIONAL DAMPER MEC ER m 22 gt NUT lt 2 N 92 71 I ACCUMULATOR OIL FILL TUBE FLEXPLATE MAIN PRESSURE AVAILABLE ON SHOWN WITH Inch series threads BOTH SIDES STARTER RING GEAR MD B 300R B 400R LEFT FRONT VIEW 01712 01 00 e z 5 lt 5 5
8. Allison Transmission Mechanic s Tips MD HD B Series Allison On Highway Transmissions MT2159EN 75238 2002 OCTOBER Mechan ICS Rev 1 2005 AUGUST Tips MT2159EN Allison Transmission Allison On Highway WTEC II Controls MD HD B Series 3000 Series except 3070 4000 Series B 300 Series B 400 Series B 500 Series Allison Transmission Allison Transmission Inc P O Box 894 Indianapolis Indiana 46206 0894 www allisontransmission com Printed in USA Copyright O 2007 Allison Transmission Inc 5 TABLE OF CONTENTS SECTION INTRODUCTION 1 1 ABOUT THIS MANUAL eo SECTION PREVENTIVE MAINTENANCE 2 1 PERIODIC INSPECTION AND CARE 2 2 IMPORTANCE OF PROPER TRANSMISSION FLUID LEVEL 2 3 TRANSMISSION FLUID CHECK 2 4 KEEPING FLUID CLEAN 2 2 2 2 5 FLUID RECOMMENDATIONS 2 6 TRANSMISSION FLUID AND FILTER CHANGE INTERVALS 2 7 TRANSMISSION FLUID CONTAMINATION 2 8 TRANSMISSION FLUID AND FILTER CHANGE PROCEDURE 2 9 FLUID LEAK DIAGNOSIS 2 10 BREATHER RC 2 11 TROUBLESHOOTING EY 2 12 TRANSMISSION STALL TEST AND NEUTRAL COOL DOWN CHECK 4 oho ee ae ed SECTION REMOVING TRANSMISSION 3 1 DRAINING TRANSMISSION 3 2 DISCONNECTIN
9. 000 00 000 00 SOMN 000 SIMIN 000 5 000 SOMN 0001 00001 S III 000721 lt 60 SH L UON x Pu Sue1 UON IMPAS eu rojug 401 401 D c MEN 0 1 ________ NOLLVOOA t NOLLVOOA SuoissiusueJ seues 00 8 006 104 79 2 1 1 27 pasn Jo 2001 YIM pue 01 pozru302o1 gt jou sourqoeur SuTYsNp 44 9 SOLOS uosr y pue pu gSuei 001 UOTSsTUISULI uo pue c ur 1910 pue Jad ouo enbo 10 utu 882 2 tod 401 1 euo wey 2 pue jrsued ABMYSIY JJO UO 5 xx SI 94109 posde o FLU smoH 0007 smoH 0002 0007 smon 0005 0002 SMOH 0002 SQUOW PC SHUCW rc SHOW Sp SHON PZ SHUN PC SUUOW vC uni 000 08 000 08 ui 000 OFZ
10. Hydraulic System for e Recommended fluid TranSynd DEXRONC III or fluid Correct fluid level in transmission Dipstick correctly calibrated Figure 2 2 e Fill tube tight e 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 e Instruments gauges and lights work correctly e Shift Selector display is on and DO NOT SHIFT light is off e Fluid temperature gauge 75 Power Takeoff if installed for Controls connected and operative Correctly coupled to driven equipment e Lubrication line correctly installed and routed if used 7 2 ROAD TEST AND VEHICLE OPERATION CHECKLIST MD HD B On Highway WTEC II Electronic Controls Operator s NOTE Refer to Allison Transmission publication number OM2157EN Manual 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 1 Check fluid Fill the transmission with the appropriate fluid Refer to Section 2 5 for fluid recommendations 2 Start the vehicle Check for proper system response during start up a Turn on the vehicle s master ignition switch b The DO NOT SHIFT light should come on c Start the engine d The DO NOT SHIFT light should go off e NN should appear in the shift selector display
11. 6 5 9 MD 3060 3560 STANDARD 4 00 in 250in 1 80 3 41 in 0230 E 101 6 mm 63 5 45 7 86 6 5 9 7 00 in MD 3070PT STANDARD 4 00in 2500 1 80 in 3 41 in 0 23 in NOTE Calibrate level marking locations with respect to transmission control module split line and fill tube Scale none Dimension determined by installation Reference dimension only Actual dimension to be determined by installation Reference drawing AS66 60 Reference drawing AS67 60 01716 01 00 Figure 2 2 Standard MD HD Product Line Dipstick Markings 24 2 5 FLUID RECOMMENDATIONS The hydraulic fluid used in the transmission is an important influence on transmission performance reliability and durability and TranSynd fluids are recommended for use in the MD HD Product Line transmissions Some fluids are also qualified as Type fluids To be sure the fluid is qualified for use in Allison transmissions do the following Check for a DEXRONC III or C4 fluid license or approval number on the container e Refer to the approved fluid list on the Allison Transmission website www allisontransmission com e Consult the lubrication manufacturer TranSynd is a full synthetic transmission fluid developed by Allison Transmission and Castrol Ltd This fluid meets Allison Transmission specifications for Severe Duty and
12. Check Procedure The neutral cool down check determines if the transmission fluid cools following an engine load condition Perform the following procedures immediately after the maximum engine rpm has been recorded in the stall test 1 Record the converter out fluid temperature 2 Reduce the engine rpm to idle and shift to N Neutral 3 Run the engine at 1200 1500 rpm for two minutes to cool the fluid 4 Record the converter out fluid temperature at the end of the two minutes Converter out fluid temperature should return to within normal operating temperature range 5 If the fluid does not cool during the two minute cool down check a stuck stator may be the source of the problem e Stall Test Results NOTE Environmental conditions such as ambient temperature J altitude engine accessory loss variations etc affect the power input to the converter Under such conditions stall speed can vary from specification by 150 rpm and still be accepted as within normal range e An engine problem is indicated if engine stall speed is more than 150 rpm below engine manufacturer s specification e If engine stall speed is more than 150 rpm above engine manufacturer s specification a transmission problem is indicated such as Slipping clutches Fluid cavitations Aeration Torque converter e An extremely low stall speed such as 33 percent of the specified engine stall rpm during which the engine
13. Complaints section These troubleshooting charts list a variety of conditions that may or may not relate to the electronic control Some conditions and suggested checks include mechanical and hydraulic items Use the diagnostic code troubleshooting information that best applies to the situation if the troubleshooting charts refer to an electronic control check Use the MD HD Product Line individual clutch apply circuit pressure taps when necessary Figure 2 6 Clutch Pressure Check Points f Troubleshooting Intermittent Diagnostic Codes Intermittent codes are a result of conditions which are not always present When conditions causing the code exist the code is logged in memory The code stays in memory until it is manually cleared or cycled out When intermittently occurring codes exist check for the following items Dirty damaged or corroded harness connectors and terminals Terminals not fully seated in connectors Damaged harnesses due to poor routing chafing excessive heat tight bends etc Improperly mounted electronic control components Poor connector seals where applicable Exposed harness wires Electromagnetic interference EMI generating components and accessories Loose dirty or corroded ground connections To help locate intermittents it sometimes helps to place the appropriate tester on the suspected component or circuit and simulate operating conditions wiggle pull bump and be
14. and Figure 3 3 For the HD B 500 disconnect the engine turbine and output speed sensors refer to Figure 3 1 NOTE There may be residual transmission fluid in the retarder accumulator hydraulic line e If a retarder is used disconnect the retarder accumulator hydraulic line from the retarder For MD B 300 B 400 disconnect the transmission external harness from the retarder connector Figure 3 2 and Figure 3 3 For the HD B 500 disconnect the retarder connector and the retarder temperature sensor connector Figure 3 1 e If a PTO s is used disconnect the PTO s wiring harness 49 BREATHER x ENGINE SPEED SENSOR FEEDTHROUGH HARNESS Y 22 Qu 7 6 NAMEPLATE COOLER GSP 2 NOTE Inch Series Threads 0 8 6 RETARDER CONNECTOR FROM COOLER 2 NOTE Inch Series Threads V01437 01 00 3 3 Figure 3 2 MDR B 300 B 400 Disconnect Locations UNCOUPLING FROM DRIVELINE ENGINE AND VEHICLE Disconnect the vehicle drive shaft from the transmission output flanges or yokes 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 Place a jack or other support under the engine if transmission mountings support the rear of the engine Securely support the transmission with a hoist jack or other suitab
15. and provide specific areas or conditions within the main code that caused the occurrence e Example Code 13 12 13 indicates a problem with ECU voltage 12 indicates the problem is caused by low voltage e Example Code 21 12 21 indicates a problem with the throttle position sensor signal 12 indicates the throttle position sensor signal is low The displayed code is currently active if the MODE ON indicator in the display window Figure 2 5 Shift Selectors is illuminated The displayed code is inactive if the MODE ON indicator is not illuminated In normal operating mode an illuminated MODE ON display indicates secondary mode operation e The Ignition Cycle Counter determines when inactive diagnostic codes are automatically cleared from the code list The counter is advanced each time a normal ECU powerdown occurs ignition turned off Inactive codes are cleared from the code list after the counter reaches 25 40 e The Event Counter counts the number of occurrences of a diagnostic code If a code is already in the code list and the code is again detected The code is moved to position 41 The active indicator is turned on The Ignition Cycle Counter is cleared The event counter is advanced one position e The ignition cycle counter and event calendar information may be accessed by using Allison DOC For PC diagnostic tool Refer to Allison DOC for PC GN3433EN for specific instructions c Clea
16. exceed 149 C 300 F During stall conditions converter out temperature rises much faster than internal temperatures Do not use internal fluid temperature to determine the length of the stall condition If the stall test is repeated do not let the engine overheat With the vehicle wheels blocked parking and service brakes applied hold the engine at wide open throttle Reduce engine rpm to idle and shift to N Neutral 6 Monitor converter out temperature 7 Proceed immediately to the procedures in Paragraph d Neutral Cool Down Check Procedure in this Section c Stall Test Smoke Controlled Engines Perform the following procedures 1 2 3 4 NOTE The stall test may have to be performed while the vehicle is moving because smoke controls and throttle delay mechanisms inhibit engine acceleration Locate an isolated area in which to perform the driving stall test Select a hold range that will limit road speed Second or third range are best but not low range because it produces very high torque Operate the engine at full throttle maximum governed speed Gradually apply the vehicle service brakes while staying at full throttle Record the engine speed rpm when the vehicle comes to a complete stop This is the engine stall speed for the engine transmission combination Proceed immediately to the procedure in Paragraph d Neutral Cool Down Check Procedure 46 d Neutral Cool Down
17. mechanic s reference for maintaining removing or installing the MD HD Product Line on highway transmissions with the WTEC II control system All features of the transmission and the vehicle involved in installation procedures are discussed The information 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 Section 8 2 Service Literature Table 8 1 for the appropriate transmission service manual and electronic control troubleshooting manual Unless specifically indicated otherwise this handbook refers to all MD HD Product Line transmissions except MD 3070 The differences between the various transmissions in this product line are explained as required Table 1 1 Abbreviations AT Allison Transmission EU Electronic Control Unit EMI Electromagnetic interference KOH Hydroxide 77 i ECU 1 1 i TAN TIR indi TPS iti VIM Oil level sensor Power Takeoff RFI EMI Radio frequency interference electromagnetic interference AN Total acid number Total indicated runout 00 TP Throttle position sensor 0001 vm Vehicle interface module 107168103 5 SNIGHNL 81081503 2 19314 0 0 JINGOW 1034405 YOSNAS T3A31 110 5 JINON 5 H31H3ANOO JING
18. port plugs loose Porous casting e Leak at converter end Converter seal damaged Seal lip cut check converter hub for damage Garter spring missing from seal Converter leak in weld area or o ring seal Porous casting e Fluid comes out of fill tube Overfilled Incorrect dipstick Plugged vent Water or coolant in fluid fluid appears milky Incorrect electronic fluid indication Drain back holes plugged 36 3 Visually inspect the suspected leaking areas including all gasket mating surfaces 4 If the source of the leak cannot be identified clean with steam or spray solvent and dry the suspected areas 5 Operate the vehicle for several miles at varying speeds Inspect the vehicle again for leaks 6 If the leak source still cannot be identified refer to Paragraph b Powder Method and or Paragraph c Black light and Dye Method to find the leaks b Powder Method e Clean the suspected area e Apply an aerosol type white powder to the suspected area e Operate the vehicle under normal operating conditions e Visually inspect the suspected area and trace the leak path over the white powder c Black light and Dye Method A dye and black light kit for finding leaks is available Refer to the manufacturer s directions when using the kit Refer to the kit directions for the color of the fluid dye mix e Pour the specified amount of dye into the transmission fill tube e Operate the vehicle under normal op
19. sensors retarder control connector retarder temperature sensor and accumulator solenoid b MD B 300 B 400 connect engine and output speed sensors retarder control connector and accumulator solenoid Connect the PTO s connector s The PTO connector is not part of the Allison Transmission external wiring harness Tighten the transmission wiring harness external connector bolts to 2 3 Nem 18 25 Ib inch Be sure the speed sensors PTO connector and other connections are securely seated and latched by pulling on the connector NOT THE WIRES On the MD B 300 B 400 turn the retarder connector if used until feeling a positive snap on the connector The transmission has a sump fluid temperature sensor on the internal wiring harness A retarder fluid temperature sensor is installed in the retarder on retarder equipped models Hot fluid conditions in the sump or retarder can be read with Allison DOC service tool by programming an output function Refer to Allison Transmission publication number GN3433EN Allison DOC for PC User Guide for specific instructions temperature gauge may be installed in the To Cooler line Temperature gauge installations are available on integral cooler installations 72 8 If equipped with capillary tube and bulb a Tightened the adapter tight enough to prevent leakage b Install the bulb into the adapter and tighten the nut c Check the capillary tube f
20. 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 ST2067EN HOLD OVERRIDE BUTTO N SELECT DIGIT DISPLAY WINDOW SELECT MONITOR DIGIT A ONITOR DIG MN EI MODE ON T N m Na DE UP DOWN DISPLAY MODE PUSHBUTTON SIX SPEED BUTTON SEVEN SpEED SELECTOR LEVER SELECTOR LEVER SELECTOR V07792 00 00 Figure 2 1 Shift Selectors 2 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 supply of fluid and the transmission overheats If the level is too high the fluid aerates causing erratic shifts overheating and exhausting of fluid through the breather or dipstick tube 2 3 TRANSMISSION FLUID CHECK a Electronic Fluid Check Procedure Fluid level information may be displayed on the shift selector Figure 2 1 if the transmission being maintained has an oil level sensor OLS If the transmission does not have an OLS refer to Paragraph Manual Fluid Check Procedure in this Section Displaying fluid level information For a pushbutton shift selector simultaneously press the T Up and 1 D
21. situation that arises in connection with the sale operation or service of your transmission will be handled by the distributor or dealer in your area Refer to Allison Transmission publication number SA2229EN Worldwide Sales and Service Directory for a current listing of Allison Transmission authorized distributors and service dealers 8 2 SERVICE LITERATURE This service literature provides fully illustrated instructions for the operation maintenance service overhaul and parts support of your transmission To be sure that you get maximum performance and service life from your transmission you may order publications from SGI Inc Attn Allison Literature Fulfillment Desk 8350 Allison Avenue Indianapolis IN 46268 TOLL FREE 888 666 5799 INTERNATIONAL 317 471 4995 Refer to Table 8 1 MD HD Product Line Service Literature for additional service literature 79 Table 8 1 MD HD Product Line Service Literature Transmission Model MD B 300 B 400 HD B 500 Automatic Transmission Fluid GN2055EN GN2055EN MEN Worldwide Sales Service SA2229EN SA2229EN Directory Also available on the internet at www allisontransmission com 80 EA i MT2159EN 200508 www allisontransmission com Printed in USA 200509
22. the following Seals Gaskets Clutch plates Torque converters that cannot be disassembled Components that have rusted Solenoids that do not meet resistance specifications Remove all traces of ethylene glycol and varnish deposits Failure to follow this procedure decreases transmission reliability and durability e e Bearings e e e Nelco Company offers a kit that detects presence of ethylene glycol in transmission fluid The kit is identified as GLY TEK Test Kit and can be obtained from Nelco Company 1047 McKnight Road South Saint Paul Minnesota 55119 651 738 2014 Some conditions that may indicate water and or glycol in the fluid are e Rust or pitted transmission parts e Transmission fluid spewing out of transmission breather e Transmission fluid in radiator Gaskets blistered or wrinkled in uncompressed areas Appearance of fluid presence of water in the fluid when dispersed is a cloudy or gray pink or strawberry color e Steam from the breather For additional information on field analysis refer to Allison Transmission publication number GN2055EN Automatic Transmission Fluid Technician s Guide This publication can be used to reference testing methods and limits for water glycol content 31 2 8 TRANSMISSION FLUID AND FILTER CHANGE PROCEDURE a Drain Fluid NOTE Do not drain transmission fluid if only the filters are being replaced 1 Drain the fluid when the transmiss
23. weight based on cold temperature properties 2 6 TRANSMISSION FLUID AND FILTER CHANGE INTERVALS a Frequency Optimum performance and reliability of heavy duty automatic transmissions can be noticeably influenced by the type of fluid used and the frequency with which the fluid is changed Allison Transmission has designed extensive programs including specifications and tests to verify the quality of fluids and consequently have specific fluid and filter change recommendations NOTE Local conditions severity of operation or duty cycle may J require more frequent or less frequent fluid change intervals that differ from the published recommended fluid change intervals of Allison Transmission With the introduction of the Gold Series filters for the MD HD Product Line transmissions the initial 5000 miles 8000 km 200 hours filter change interval has been modified to require changing the main filter only Table 2 6 and Table 2 7 list current fluid and filter change recommendations based on vocation If fluid change intervals are extended by fluid analysis transmission filters must be changed at or before recommended filter change intervals Refer to Allison Transmission publication number GN2055EN Technicians Guide to Automatic Transmission Fluid for additional information on fluid analysis and general knowledge about engine oils and transmission fluids optimized by the use of fluid analysis However filters must be change
24. 10184819 and HD B 500 Series before S N 6610038064 Install flange or yoke onto output shaft Install the large O ring on the retainer plug Install a belleville washer on each bolt so that the coned end of the washer contacts the underside of the bolt head Insert two bolt washer assemblies into the bolt holes in the plug Install a small O ring over the threads of each bolt so that the O ring seats against the retainer plug Install retainer plug and bolts into the flange or yoke Tighten bolts to 30 35 Nem 22 26 Ib ft for an MD B 300 B 400 3000MH Series transmission Tighten bolts to 51 61 Nem 38 45 Ib ft for HD B 500 4000 Series transmission Rotate the flange or yoke to check for binding MD B 300 B 400 Series beginning with S N 6510184819 and HD B 500 Series beginning with S N 6610038064 and all MH Series Install flange or yoke onto output shaft Install the large O ring on the retainer plug Insert one bolt into the bolt hole in the plug Install a small O ring over the threads of the bolt so that the O ring seats against the retainer plug Install retainer plug and bolt into the flange or yoke Tighten bolt to 70 80 Nem 52 59 Ib ft 4 3 INSTALLING PTO Access to the PTO mounting pads and the space available to maneuver the transmission determines whether the PTO should be installed before or after the transmission is installed CAUTION DO NOT use cork or other soft gaskets to i
25. 80 56 2 T33HMA14 6671 pg PN YAHSV Mbox 0 30 32 4 26271 pach H3HSVAF8L 68 44 2 utu 0066 urgize gz 1g a l 8076 95 98 Figure 5 2 HD B 500 Engine Adaptation 60 T EZ 4 21 V01717 01 00 Figure 5 3 Converter Axial Location Measurement g Crankshaft Hub Pilot or Adapter Concentricity The crankshaft hub pilot or the hub adapter pilot concentricity cannot exceed 0 13 mm 0 005 inch TIR h Flexplate Bolt Hole Flatness Flexplate flatness in the area of the bolt holes is not a measurement required for the MD HD Product Line 1 Torque Converter Axial Location Measure from the face of the torque converter housing to the torque converter flexplate adapter mounting face using a depth gauge Refer to Figure 5 3 The torque converter axial location should measure MD B 300 B 400 Series transmission 50 76 mm 2 0 inches e HD B 500 Series transmission 45 54 mm 1 80 inches 5 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 Be sure engine crankshaft end play is within the engine manufacturer s specifications 61
26. C IN CAB TRANSMISSION CONTROLS AN VEHICLE WIRING HARNESS RETARDER ACCUMULATOR 3 AND MOUNTING BRACKETS Mount accumulator horizontal to frame or SUPPLY HOSE ber Centerline of lat SAE 6 SIZE MINIMUM crossmember Centerline of accumulator MAXIMUM LENGTHS shall be no higher than top of transmission 12m 39 4 ft RETARDER SOLENOID NORMALLY CLOSED eeu PRESSURE PROTECTION VALVE 85 PSIG MAXIMUM CLOSING PRESSURE SOCIETY OF AUTOMOTIVE ENGINEERS 1 625 in STRAIGHT THREAD O RING CONNECTION IN SERIES THREAD Torque fittings to 68 81 N m 50 60 LB FT NUMBER 20 MINIMUM HOSE SIZE 1 125 in MINIMUM INSIDE DIAMETER MAXIMUM HOSE LENGTH 1 8 m 6 ft Tie down center of hose if longer than 0 9 3 ft RETARDER TEMPERATURE SENSOR RETARDER TURBINE SPEED MODULE SENSOR SENSOR CONNECTOR ENGINE SPEED SENSOR V00427 02 00 Figure 4 1 Output Retarder Accumulator Installation PREPARING VEHICLE Section FOR TRANSMISSION imm A INSTALLATION OS Me 5 1 ENGINE TRANSMISSION ADAPTATION REQUIREMENTS You must be sure a new transmission installation can be adapted to the vehicle s engine The measurements listed in this section describe the correct engine to transmission adaptation Refer to Figure 5 1 or Figure 5 2 and or 567 020 Measuring Equipmen
27. D B 500 400 T 500 LUBE MD B 300 B 400 T 200T 300 Main and Lube Filter designations cast into bottom of Control Module V07268 01 00 Figure 2 3 Location of Filters for Service CAUTION Do not use the bolts to draw the filter covers to the control module Do not use an impact wrench to tighten the bolts Using an impact wrench to tighten the bolts can strip threads and cause expensive parts replacement Use a torque wrench to tighten the bolts For all transmissions 1 Install filter and cover assemblies into filter compartment 2 Align each filter cover assembly with the holes in the channel plate sump and push the cover assembly in by hand to seat the seals 3 Install six bolts into each cover and tighten to 51 61 Nem 38 45 lb ft 33 4 Replace control module drain plug O ring and transfer case drain plug if equipped 5 Install the plug s and tighten to 25 32 Nem 18 24 lb ft c Refill Transmission Fluid remains in the torque converter external circuits and transmission cavities after draining the transmission There the amount of refill fluid will be less than the amount used for the initial fill Refer to Figure 2 4 Sump Identification for sump identification and Table 2 10 Transmission Fluid Capacity for fluid fill quantities Check the fluid level using the procedures in Transmission Fluid Check Paragraph a Electronic Fluid Check Procedure through Paragraph d Hot Check Proced
28. E gt a 5 rin 528 22 5 zo 5 5 na 2 5 3 A 55 ex gt gt 2 f Wy 5 E gt FEEDTHROUGH HARNESS CONNECTOR TURBINE SPEED A B 4 19 q OY 29 SY 2 Zz Wi Vu d FILL TUBE NAMEPLATE 22 9 9 SENSOR OUTPUT SPEED COOLER PORTS REAR VIEW 500 RIGHT lt 0 On 27 a e gt a oe z N Y SS CAS A s M SG e NC ENSE A COOLER PORTS 2 22 RUE FE PTO BOTTOM LEFT POSITION MAIN PRESSURE TAP REAR VIEW B 500P LEFT V01713 01 00 WIRING HARNESS BRACKET SHIPPING BRACKET 3 TRANSMISSION AN 20 ELECTRICAL j M CONNECTOR 4 WI MOUNTING PAD ENGINE SPEED SENSOR TURBINE SPEED SENSOR OUTPUT SPEED SENSOR COOLER PORTS unti NAMEPLATE MOUNTING PAD BOTH SIDES S pe TRANSMISSION Sei ANM 2 ELECTRICAL NN CONNECTOR PTO BOTTOM LEFT POSITION 0 COOLER PORTS MAIN PRESSURE TAP HD 4060P 4560P LEFT REAR VIEW V01714 01 00 RETARDER PTO FEEDTHROUGH HARNESS MOUNTING PADS BOTH SIDES NAMEPLATE TRANSM
29. EDOMETER 6 10 CONNECTING ELECTRICAL COMPONENTS 6 11 FILLING HYDRAULIC SYSTEM 6 12 INSTALLATION CHECKLIST SECTION CHECKS AND ADJUSTMENTS 7 1 INSTALLATION CHECKLIST zr Rt ERR 7 2 ROAD TEST AND VEHICLE OPERATION CHECKLIST SECTION VIII CUSTOMER SERVICE 8 1 OWNER ASSISTANCE Loca eas y des 8 2 SERVICE LITERATURE TRADEMARK USAGE The following trademarks are the property of the companies indicated is a registered trademark of the General Motors Corporation e TranSynd is a trademark of Castrol Ltd e Allison DOC is a trademark of General Motors Corporation LPS Electro Contact Cleaner is a registered trademark of LPS Laboratories WARNINGS CAUTIONS 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 Allis
30. Extended Drain Intervals TranSynd is fully qualified to meet the GM or C4 specifications and is available through Allison Transmission distributors and dealerships Transmissions that have factory fill TranSynd can be identified by the transmission name tag on the side of the main case showing date code 02A02 02 year A January 02 day or later This code will also confirm MD HD Product Line transmissions that have been equipped with the high capacity Gold Seal main and lube oil filter in transmission malfunction or reduced transmission life CAUTION Disregarding minimum fluid temperature limits can result When choosing the optimum viscosity grade of fluid to use the following must be taken into consideration e Duty cycle e Preheat capabilities Geographic location Table 2 5 Transmission Fluid Operating Temperature Requirements 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 N Neutral for a minimum of 20 minutes before attempting range operation 25 Table 2 5 Transmission Fluid Operating Temperature Requirements I Minimum Operating Temperature AE SAE Viscosity Gr de Celsius Fahrenheit MIL PRF 46167 SAE 0W 20 TranSynd DEXRON III 30 20 gt SAE W designation indicates winter
31. G CONTROLS 3 3 UNCOUPLING FROM DRIVELINE ENGINE AND VEHICLE 3 4 REMOVING THE TRANSMISSION 3 5 REMOVING OUTPUT FLANGES YOKES SECTION IV TRANSMISSION PREPARATION 4 1 CHECKING INPUT COMPONENTS 4 2 INSTALLING OUTPUT FLANGE OR YOKE 4 3 INSTALLING Ne alan 4 4 INSTALLING FILL TUBE AND SEAL 4 5 CHECKING PLUGS AND OPENINGS 4 6 OUTPUT RETARDER ACCUMULATOR INSTALLATION REQUIREMENTS ay DAR ER MES ROAD EROS SECTION V PREPARING VEHICLE FOR TRANSMISSION INSTALLATION 5 ENGINE TRANSMISSION ADAPTATION REQUIREMENTS 5 2 CHECKING FLEXPLATE DRIVE ASSEMBLY 5 3 CHASSIS AND DRIVELINE INSPECTION 5 4 COOLER FILTER AND LINES 2 2 2 5 2 6 4 255 CHECKING CONTROLS btana OS x SECTION VI INSTALLING TRANSMISSION INTO VEHICLE HANDLING 215 23 eee jor ead 6 2 MOUNTING TO ENGINE 64365406440 65009 6 3 INSTALLING TRANSMISSION MOUNTING COMPONENTS 6 4 COUPLING TO DRIVELINE 6 5 CONNECTING OUTPUT RETARDER ACCUMULATOR 6 6 CONNECTING POWER TAKEOFF CONTROLS 6 7 CONNECTING PARKING BRAKE CONTROL 6 8 CONNECTING COOLER 6 9 CONNECTING SPE
32. ISSION ELECTRICAL CONNECTOR HD 4060PR 4560PR RIGHT FRONT VIEW MOUNTING PADS BOTH SIDES PTO BOTTOM LEFT POSITION MAIN PRESSURE TAP 4060PR 4560PR LEFT REAR VIEW V07791 02 00 PREVENTIVE MAINTENANCE 2 1 PERIODIC INSPECTION AND CARE Clean and inspect the exterior of the transmission at regular intervals Severity of service and operating conditions determine the frequency of these inspections Inspect the transmission for Loose bolts transmission and mounting components Fluid leaks repair immediately Loose dirty or improperly adjusted throttle sensor Damaged or loose hoses Worn frayed or improperly routed electrical harnesses e Worn or out of phase driveline U joints and slip fittings e Clogged or dirty vent breather e Check the vehicle cooling system for evidence of transmission fluid Transmission fluid in the vehicle cooling system indicates a faulty oil cooler CAUTION When welding on the vehicle DO NOT WELD on the vehicle without disconnecting all control system wiring harness connectors from the ECU DO NOT WELD on the vehicle without disconnecting ECU battery power and ground leads DO NOT WELD on any control components DO NOT CONNECT welding cables to any control components PROTECT CONTROL COMPONENTS FROM SPARKS AND HEAT DURING WELDING A label describing on vehicle welding precautions is available from authorized Allison service dealers and
33. N3S 13 31 710 310G0 Ld JINGOW NNS NNS LAVHS JTNGOW LAVHS NIVIN YOLVLS YAdWVO HOLNTO 201 58 5 1 80108 HOLNTD SO V FINGOW H31H3ANOO A18N3SSV HOlVlS H91019 v9 uaquviad 9 5 SNISNOH NIVIA NOILO3S 55 NOISSINSNVH I 4005 110 1404418 110 1909905 1 084 11 20 00S00A 13 5 ANIGYNL H LNTO H LNTO 9 JTINGOW H LNTO 9 10 5 YALYSANOD 81081 03 2INOHL23T3 OHQAH 310GONW 9 H31H3ANOO JINGOW 71034405 5 35 13 31 10 Ld NOLSId 83 JINGOW d LAVHS LAdLNO JINON NNS d za 14VHS HOLVLS 13 f ey E JINGOW H31H3ANOO HOLNTD 110 69 5 NIYIN 14044105 LNOYS 5 NIVIA 110 190 1NOU3 NOILO3S 55099 NOISSIINSNVYL 099 12 BREATHER ASSEMBLY PADS
34. OW 14 NNS 64 NNS LAVHS NIV JTINGOW LAVHS 55 SNISNOH 80108 55 01 15 88 1 JINGOW YALYSANOD 110 5 NIVIN 1 04418 LNOYS SNISNOH NIVIA 18084 NOILO3S 55099 NOISSIINSNVYL 3007 8 H00 8 H090 L4VHS SNIGYNL HOLNTO 10 ONLLWLOY 5 H31H3ANOO 81081 2INOHLIO3T13 0HQAH JINGOW 5 YALYSANO9 JINON 1031105 uOSN3S 13 31 110 JINGOW 14 NOLSId SO 14 6 104100 JINON H3A02 MES a NNS 64 NNS YOLVLS 13 NIVIN JINGOW LAVHS NIYIN x JINON 9 10 NIYIN 1 311400 NIVN 01404408 14084 NOILO3S 55049 NOISSINSNVHL 009 10 6810 13 5 ANIGYNL H91019 Z HOLATD 19 JINGOW HO1019 9 10 SNISNOH YALYSANOD JTINGOW 5 Y3LYSANO9 81081 9 0415313 1081 uOS
35. WWIXVIN 50070 ero 66 08 t6 0S C 19 sounjoejnuew euj amp ue 1108 1JVHSXNVHO 31V1d aix uonisod 10 MIIA 99 Gt 14 SNH LJVHSNNVHO 81010 Buraq 1 apisyno y yns 1648 uBis q ur 8081 ze s 1 NO HOLVOIGNI WLOL sooo E 81 12 WAN 62 72 OL 300801 y 13 81 12 1 UN 62 02 OL 1 41860 092 X 681 X SH19N31 X 521 1108 31V1dX314 01 31V14X314 T 683204 271 __ MD 31V1d4X314 uonisod 1eidepe VE ONN 01 94870 leldx l4oj 8 eos 1108581 gd V 1 ul 6100 82 0 14 81 86 WN 19 18 OL 31080 ge 9 Bulag episino 1 0350 51108 1708 1222 lt ww osz y peys ufjseg 99
36. adaptor 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 flywheel 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 Inspect 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 4 2 INSTALLING OUTPUT FLANGE OR YOKE a Output Oil Seal Check the output oil seal for leaks or damage Refer to Service Literature Table 8 1 for the appropriate service manual for replacement instructions Lubricate the oil seal with high temperature grease or transmission fluid if it is not being replaced 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 b 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 53 Install Output Flange or Yoke MD B 300 400 Series before S N 65
37. ain as necessary to bring it to the middle of the COLD RUN band Perform a hot check at the first opportunity after the normal operating sump temperature of 71 93 160 F 200 F is reached 22 4 Hot Check Procedure Operate the transmission in D Drive until normal operating temperatures are reached sump temperature 71 93 160 F 200 F converter out temperature 82 C 104 C 180 F 220 F Park the vehicle on a level surface and shift to N Neutral Apply the parking brake and or emergency brakes and chock the wheels Allow the engine to idle 500 800 rpm With the engine running remove the dipstick from the tube and wipe clean Insert the dipstick into the tube until it stops and remove Check fluid level reading Repeat the check procedure to verify the reading dipstick The HOT RUN band is between the HOT FULL and the HOT ADD bands Refer to Figure 2 2 NOTE Safe operating level is within the HOT RUN band on the e 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 Refer to Figure 2 2 Standard MD HD Product Line Dipstick Markings e Consistency of Readings Always check the fluid level at least twice with the engine running Consistency repeatable readings is important to maintaining proper fluid level If inconsistent readings persist check the trans
38. alarm sounds This alarm continues until the shifter is moved back to the position it was in when the light came on initially The pushbutton shift selector does not have an alarm if another range is selected when DO NOT SHIFT is indicated e If the ignition is turned OFF and then ON while DO NOT SHIFT is displayed the transmission will remain in N Neutral until the diagnostic code is cleared Anytime the DO NOT SHIFT light is displayed the ECU logs a diagnostic code in memory These diagnostic codes can be accessed through Allison DOC service tool or the shifter selector NOTE Diagnostic codes can be logged without illuminating the DO J NOT SHIFT light This occurs when the ECU senses a problem but determines the problem will not cause immediate transmission damage or dangerous performance 39 b Diagnostic Codes Overview Table 2 11 Diagnostic Codes Overview Accessible by Allison Displayed on shift selector EE DOC service tool only Ignition Code List Active Cycle Position Indicator gt Counter YES MODE ON displayed Diagnostic codes are listed in memory Up to five codes can be stored with the most recent code stored listed first Diagnostic codes consist of a two digit main code and a two digit sub code Table 2 11 Diagnostic Codes Overview Main codes are listed first and provide the general condition or area of a fault detected by the ECU e Sub codes are listed second
39. anufacturer 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 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 per manufacturer s specifications 63 e Hydraulic lines Check for contamination Clean and flush as necessary Inspect for deterioration Inspect for faulty connectors or kinks b After Overhaul A complete cleanup of the transmission system after an overhaul cannot be assumed Repeated cleaning and flushing may not remove all debris from the transmission fluid cooler system Replace the transmission from cooler oil filter after 8000 km 5000 miles Refill the transmission to the correct fluid level refer to Section 2 8 Transmission Fluid and Filter Change Procedure Refill Transmission 5 5 CHECKING CONTROLS a Inspection Inspect the following and correct any faulty conditions e Shift selector Improper operatio
40. any time FULLY EXTENDED FORCE REQUIRED 26 7 N 6018 MAX FULLY RETRACTED MOUNTING LENGTH CLOSED THROTTLE 47 5 mm 1 87 in gt 95 2 mm 3 75 in FULL THROTTLE 118 1 mm 4 65 in OPERATING BAND 22 9 mm 0 9 in 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 i 222 within this range gt gt Attach to engine or governor 30 2 mm 1 19 in 93 45 mm 3 679 housing using clamp and shims as 87 15 mm 3 431 required Clamp must positively Fuel lever attachment linkage or bracket must lock in cable groove allow fuel lever to return to closed throttle position HITCH PIN CLIP when sensor rod is maintained at full throttle position Attach the throttle sensor directly to the engine fuel ENGINE FUEL LEVER lever with no breakover or yield linkages between the engine fuel lever shaft and the attachment point of the throttle sensor CLOSED THROTTLE lt 183 1 mm 7 21 in MAX FULL THROTTLE SAME AS C 160 2 mm 6 31 in SLIP LINK FULLY EXTENDED y EEEE 38 1 mm 1 50 in j FULLY OPTIONAL THROTTLE SENSOR ASSEMBLY WITH SLIP LINK HITCH PIN CLIP V00430 01 00 Figure 5 5 Hitch Pin Throttle Position Sensor Installation Diagram 66
41. ct the hydraulic hose between the retarder and the accumulator Tighten hose fittings to 68 81 Nem 50 60 lb ft 69 6 6 CONNECTING POWER TAKEOFF CONTROLS Mount the PTO s onto the transmission refer to 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 CAUTION 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 can cause inadvertent clutch apply and PTO damage 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 6 7 CONNECTING PARKING BRAKE CONTROL 1 Connect and properly adjust the parking brake 2 Adjust the brake shoe to drum clearance as specified by the manufacturer This does not apply to HD B 500 Series off and on highway transmissions 6 8 CONNECTING COOLER Refer to for typical cooler port locations and torque values 6 9 CONNECTING SPEEDOMETER DRIVE The ECU through the vehicle interface module VIM provides an electronic speedometer speed signal Co
42. ction Transmission removal should occur only if the additional investigation warrants it Water Engine Coolant Contaminant The presence of water and or ethylene glycol coolant mixture in the transmission fluid is detrimental to the reliability and durability of the internal components Contaminated fluid has a deteriorating effect on the transmission components Frictional capacity of drive clutch plates can be greatly reduced as a result of surface film or impregnation and the presence of glycol will physically deteriorate clutch plate materials If contamination is suspected a fluid sample should be obtained when transmission fluid is at normal operating temperature to be sure a contaminant if present is thoroughly dispersed in the fluid being sampled The analysis of the sample by the fluid supplier or any qualified laboratory will provide the degree of contamination and possibly a clue as to its source A minimal amount of water and glycol may be due to one or all of the following e Uncovered oil drums e Open transmission fill tube Glycol from an all purpose fill container Defective transmission oil cooler 30 Fluid contamination greater than 0 2 percent water by volume regardless of whether it contains glycol is considered contaminated and should not be used CAUTION If the transmission fluid is contaminated by water 0 2 percent by volume or any trace of ethylene glycol disassemble the transmission and replace
43. d NOTE Transmission protection and fluid change intervals can be at or before recommended intervals 26 jo 9 001 YIM sorouojsrsuoour pue jou Surusn 44 SOLIS p or uorssrursue1 UOSTTPY pue pu suei 2500 Sururejuoo uorssrursue uo poseq suongeooA pue Jad 1 ouo 10 uey 559 qoeoo 194 401 1 ouo 1 18 qoeoo pue sue ABMYSIY JJO UO 5 souroo pesde o savy sujuour FLU 0006 000 0008 000 0006 SIT oH 0006 9 9 gt Suo 9 Suo 9 Suo 9 000 00 000 02 000 OFZ 000 00 000 OZ 000 00 000 SL SOTA OOO SL SN 000061 SN 000 6 S N OOO SL SPIN 000 SL S67 5 1 ic IMPAS 0001 smoH 0001 smog 0001 oos smoH 005 sinoH 006 SUON spuoW syIUO Suon 9 9 SUON 9 tu 000 0 000 OF 000 08 000 00
44. does not smoke could indicate a freewheeling stator in the converter e Perform a neutral cool down check if engine stall speed tests meet specifications but causes the transmission fluid to overheat e An electronic control problem may exist if engine stall speed meets the specification and the cool down check shows that transmission fluid cools properly Refer to Allison Transmission publication number TS2470EN MD HD B Series WTEC II Electronic Controls Troubleshooting Manual 47 REMOVING TRANSMISSION 3 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 Section 2 7 Transmission Fluid Contamination Paragraph a Monitoring Contaminant Levels through Paragraph Water Engine Coolant Contaminant Install the drain plug e 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 lines when they are disconnected from the transmission e 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 e If an integral cooler is used drain coolan
45. e sure the following conditions do not exist e Misalignment or obstruction to smooth movement through the full stroke e Idle and full throttle positions are not within an error zone Error codes occur if the idle position is less than 14 counts or when the full throttle position is more than 233 counts Hitch Pin Throttle Position Sensor Installation e Install the throttle sensor body as follows 1 Clamp cable end using clamp and shims refer to Figure 5 5 2 Secure the sensor body using the mounting holes provided 3 Install a heat shield if any part of the throttle sensor is near the exhaust manifold turbochargers or any other heat source 65 BENDING LOAD APPLIED UNACCEPTABLE INSTALLATION 10 0 MAX INSTALLED MOUNTING PROVISION OPERATING ANGLE Use M6 X 1 00 or 0 250 20 in series bolts IN ALL DIRECTIONS 3 places Torque M6 X 1 00 bolt to 10 13 N m 84 120 LB IN Torque 0 250 20 in series bolts to 108 132 LB IN Mount to a solid frame member Flatness of chassis mounting surface must not exceed 0 8 mm 0 03 in 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 R 152 0 mm 6 00 in MIN REMOVAL the closed throttle position ALLOWANCE RADIUS at
46. em 50 60 Ib ft Cooler port cover bolts tighten to 51 61 Nem 38 45 Ib ft External harness to transmission connector bolt tighten to 1 2 Nem 18 25 Ib ft Flexplate adapter to converter cover bolts tighten to 24 29 Nem 18 21 Ib ft Flexplate to crankshaft hub bolts consult engine manufacturer specifications Flexplate to flexplate adapter bolts tighten to 12 design24 29 Nem 18 21 Ib ft 6 bolt design5 1 61 Nem 38 44 Ib ft Fluid drain plug tighten to 25 32 Nem 18 24 Ib ft Fluid fill tube bracket tighten to 24 29 Nem 18 21 Ib ft Speed sensor bolts tighten to 24 29 Nem 18 21 Ib ft Output flange bolts tighten to MD B 300 B 400 Series transmission 30 35 Nem 22 26 Ib ft 500 Series transmission 51 61 Nem 38 45 Ib ft 74 e PTO cover bolts tighten to 51 61 Nem 38 45 lb ft PTO mounting bolts tighten to 51 61 Nem 38 45 Ib ft PTO pressure hose to transmission tighten to 10 13 Nem 7 10 Ib ft e Rear cover bolts tighten to 90 110 Nem 66 81 Ib ft Throttle position sensor TPS to transmission bracket tighten to 108 122 Nem 80 90 Ib ft Cooler Fluid Lines and Air Hose for No leaks e Connection tightness Correct routing Throttle Position Sensor for e Proper adjustment Correct routing of cable and harness Driveline for e Proper indexing of universal joints e Proper drive shaft angles e Driveline backlash e Lubricated universals and slip joints
47. erating conditions e Direct the black light toward the area suspected of leaking Dyed fluid will appear as a brightly colored path leading to the leak d Repairing the Leak Once the leak has been traced back to its source inspect the leaking part for the following conditions and repair as indicated Gaskets Fluid level pressure is too high Plugged vent or drain back holes Improperly tightened fasteners or damaged threads Warped flanges or sealing surfaces Scratches burrs or other damage to sealing surfaces Damaged or worn out gasket Cracked or porous casting Improper sealant used where applicable 37 Seals Fluid level pressure is too high Plugged vent or drain back hole Damaged seal bore Damaged or worn out seal Improper installation Cracks in component Output shaft surface scratched nicked or damaged Loose or worn out bearing causing excess seal wear e Sealing Flange Inspect the sealing flange for bends replace the sealing flange if bent 2 10 BREATHER a Location and Purpose The breather is located on top of the transmission converter housing The breather prevents air pressure buildup within the transmission and its passage must be kept clean and open b Maintenance CAUTION Do not spray steam water or cleaning solution directly at the vent assembly breather Spraying steam water or cleaning solution at the vent a
48. erty damage caused by unexpected vehicle movement by doing the following when checking transmission fluid level e Put the transmission in N Neutral e Apply the parking brake emergency brakes and make sure they are properly engaged e Chock the wheels and take any other steps necessary to keep the vehicle from moving c Cold Check Procedure The purpose of the cold check is to determine if the transmission has enough fluid to be safely operated until a hot check can be made CAUTION DO NOT fill the transmission above the COLD RUN band if the transmission fluid is below normal operating temperatures During operation an overfull transmission can become overheated leading to transmission damage e Park the vehicle on a level surface Apply the parking brake and chock the wheels e Run the engine for at least one minute Shift to D Drive then to N Neutral and then shift to R Reverse to fill the hydraulic system Shift to N Neutral and allow the engine to idle 500 800 rpm With the engine running remove the dipstick from the tube and wipe it clean Insert the dipstick into the tube until it stops and remove Check the fluid level reading Repeat the check procedure to verify the reading If the fluid level is within the COLD RUN 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 RUN band add or dr
49. ghten flexplate to flexplate adapter bolts until all of the bolts have been installed and tightened finger tight 8 Rotate the engine crankshaft to install the remaining self locking bolts into the flexplate adapter 9 Install the flywheel housing access cover 6 3 INSTALLING TRANSMISSION MOUNTING COMPONENTS CAUTION Use the type and grade of mounting bolts recommended by the vehicle manufacturer 1 Install all bolts washers spacer isolators or supports required to support the transmission in the vehicle frame 2 Tighten the bolts to the torque values recommended by the vehicle manufacturer 6 4 COUPLING TO DRIVELINE 1 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 2 Check the universal joint angularity of all U joints in the driveline Determine if they are within specification 6 5 CONNECTING OUTPUT RETARDER ACCUMULATOR The output retarder is connected to the vehicle air system by an air supply line attached to the retarder control solenoid mounted on the end of the retarder accumulator Figure 4 1 NOTE Be sure a one way check valve is correctly installed between the vehicle brake air system and the accumulator control solenoid 1 Connect the air supply hose fitting to the retarder air control solenoid Tighten the fitting to 16 22 Nem 12 16 lb ft 2 Conne
50. ion is at normal operating sump temperature 71 939 160 F 200 F Hot fluid flows faster and drains more completely 2 Remove the drain plug from the oil pan and allow the fluid to drain into a suitable container 3 Examine the fluid as described in TRANSMISSION FLUID CONTAMINATION Paragraph a Monitoring Contaminant Levels Monitoring Wear and Paragraph Water Engine Coolant Contaminant b Standard Fluid Filter Change Procedure Figure 2 3 e MD B 300 B 400 Series transmissions before S N 6510069120 and HD B 500 before S N 6610009730 1 Remove twelve bolts 1 two filter covers 2 two square cut seals 4 two o rings 5 and two filters 6 from the bottom of the control module 2 Lubricate and install two new o rings 5 3 Install a square cut seal 4 onto each cover 2 4 Lubricate o ring inside of main filter 6 and install onto main filter cover 2 5 Align holes in filter cover 2 with holes in control module e MD B 300 B 400 Series transmission beginning with S N 6510069120 and HD B 500 beginning with S N 6610009730 1 Remove twelve bolts 1 two filter covers 2 two gaskets 3 two o rings 5 two o rings 4 and two filters 6 from the bottom of the control module 2 Lubricate and install new o rings 4 and 5 onto each cover 2 3 Lubricate o ring inside of main filter 6 and push a filter onto each cover 2 4 Install new gasket 3 on each cover 2 and align holes in gasket with holes in cover 32 H
51. lation path b Control of Transmission Movements Use a hoist or transmission jack that allows precise control of transmission movements during installation 6 2 MOUNTING TO ENGINE Use the following procedure to mount the transmission to the engine 1 Align one of the flexplate bolt holes with the access opening at the front of the engine flywheel housing 2 Lubricate the center pilot boss with molybdenum disulfide grease Molycote G or equivalent 3 Push the transmission toward the engine while guiding the pilot boss on the torque converter into the flexplate hub adapter and the guide bolt into the hole on the flexplate 4 Seat the 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 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 5 Align the bolt holes in the converter housing with those in the engine flywheel housing 6 Install all transmission to engine bolts finger tight 7 Tighten four bolts at 90 degree intervals around the converter housing bolt circle Use the torque specified by the engine or vehicle manufacturer usually M10 1 5 6H bolts tighten to 36 61 Nem 27 45 lb ft or 7 6 14 bolts tightened to 73 88 Nem 54 65 lb ft 68 NOTE DO NOT ti
52. le removal equipment Remove all bolts nuts washers spacers and supports that attach the transmission to the vehicle and the engine 50 TRANSMISSION CONNECTOR V01897 01 00 Figure 3 3 MD B 300 B 400 Transmission Connector Before S N 6510032369 3 4 REMOVING THE TRANSMISSION Move the transmission away from the engine approximately 110 mm 4 35 inches 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 3 5 REMOVING OUTPUT FLANGES OR YOKES Output flanges or yokes may need to be transferred to the replacement transmission e The MD Series transmission output flanges or yokes are attached by two MIO x 1 5 bolts tightened to 30 35 mm 22 26 Ib ft and includes locktab e HD Series transmission output flanges or yokes are attached by two M10 x 1 5 bolts tightened to 51 61 mm 38 45 Ib ft and includes a locktab e Remove dirt and burrs from the shaft threads Loosen the nut until there is about inch gap between the nut and flange 51 Check the running torque as the nut is being removed The running torque must be at least 19 5 14 Ib ft Discard the nut if it does not meet the running torque limit 52 TRANSMISSION PREPARATION Section IV 4 1 CHECKING INPUT COMPONENTS a Bolt Holes Check all bolt holes on the front of the flywheel converter cover flexplate
53. mission breather to be sure it is clean and unclogged 2 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 and some seals to fail 23 MD B 300 400 TRANSMISSION HD B 500 TRANSMISSION e 6 35 mm 0 250 in REFERENCE Blade can be as narrow as 4 76 mm 0 187 in 2 FILL 1 I TRANSMISSION CONTROL MODULE SPLIT LINE OIL SUMP TRANSMISSION SUMP DIMENSION DIMENSION DIMENSION DESCRIPTION B FY 106 7 mm 76 2 mm 66 0 mm 132 6 mm 13 8 mm All HD B 500 4200 300 2 60 in 52210 0 54 in 5 101 6 mm 73 7 mm 50 8 mm 86 6 mm 5 9 300 B 400 STANDARD 4 00in 290in 2 00 in 3 41 in 0 23 in 2 101 6 63 5 45 7 86 6 5 9mm 300 400 DEEP OPTIONAL 4 00 in 250 1 80 3 41 in 0230 86 6 mm 5 0 in 3 41 in 023 0 4 101 6 73 7 50 8 mm MD 3060 2560 SHALLOW OPTIONAL 4 99 in 290 20010 f 101 6 63 5 457 86
54. n Poor electrical connections Improper harness routing e Cab and chassis wiring harness Poor electrical connections Frayed insulation Wiring damage Throttle sensor components Freedom of movement Improper routing Bellows damage Improper or loose cable mounting PTO controls Damage Wear Improper operation Lubrication Electrical harness connections and wiring damage 64 Retarder Controls Damage Wear Poor electrical harness connections Frayed insulation Wiring damage e Temperature gauge Capillary tube damage if used Sensor damage e Fluid pressure gauge tubing Damage Kinks Improper routing b Throttle Position Sensor TPS Adjustment Using Diagnostic Tool The throttle position sensor TPS should not need adjustment if properly installed by the equipment manufacturer If TPS adjustment is necessary confirm that it has been installed to AT specification Figure 5 5 The TPS is self calibrating and therefore has no optimum closed throttle or full throttle count value Idle count should be 50 or higher and full throttle count 200 or lower The TPS is set correctly as long as the counts are in the 50 and 200 range with a difference of 85 to 130 counts between closed and full throttle The Allison DOC service tool can read TPS counts Watch the TPS movements as the controls move it through a full stroke B
55. nd while watching the tester 43 MD B 300 B 400 C6 MD 3070PT ONLY 1 07868 01 00 Figure 2 6 Clutch Pressure Check Points g Exiting Diagnostic Mode To exit the diagnostic mode do one of the following Figure 2 5 Shift Selectors Do nothing wait until the calibrated time has passed and the system automatically returns to normal operation e A pushbutton shift selector requires one of the following actions Simultaneously press the T Up and Down arrow buttons Press N Neutral D Drive or R Reverse 44 A lever shift selector requires one of the following actions Press the DISPLAY MODE button once Move the selector lever to any position other than the one it was in when the diagnostic display mode was activated 2 12 TRANSMISSION STALL TEST AND NEUTRAL COOL DOWN CHECK a Purpose A stall test is used to determine if unsatisfactory performance is caused by the engine or transmission A neutral cool down check is a two minute cooling period after a stall test to gather fluid temperature data for troubleshooting The engine stall rpm under load is compared to the engine manufacturer s specified rpm for the stall test stall test This data can be obtained from
56. nds until the MODE button is pressed again 3 Momentarily press the MODE button to move to the next code stored in memory 4 When all codes have been retrieved the display will return to the first code listed and repeat the sequence RECORD ALL CODES 41 NOTE Use Allison DOC service tool to clear and retrieve the troubleshooting codes Refer to Allison Transmission publication number GN3433EN User s Guide for specific instructions Troubleshooting When No Diagnostic Codes Are Present e Always start with the basics Make sure the shifter is in the appropriate range Check fluid level Make sure batteries are properly connected and charged Make sure electrical connections are properly made Check support equipment for proper installation and operation e If the shifting process is rough give the shifts time to converge before assuming there is a problem HOLD OVERRIDE BUTTON DISPLAY WINDOW SELECT DIGIT N MONITOR DIGIT MODE ON INDICATOR MODE BUTTON je MODE imac BUTTON DISPLAY e MODE PUSHBUTTON SIX SPEED BUTTON SEVEN SPEED SELECTOR LEVER SELECTOR LEVER SELECTOR V07792 00 00 Figure 2 5 Shift Selectors 42 Refer to Allison Transmission publication number TS2470EN MD HD B Series WTEC II Electronic Controls Troubleshooting Manual under the General Troubleshooting of Performance
57. nsmission can be detrimental to continued operation Contaminant limits are shown in Table 2 9 Contaminant Limits Examine the fluid at each fluid and or filter change for contaminants 29 Table 2 9 Contaminant Limits Glycol No trace allowed Alien fluids If detected change transmission fluid Any fluid not included on the Allison C4 Approved Fluids List The Approved Fluids List may be found at Allison Transmission website www allisontransmission com b Monitoring Wear Absolute maximum values cannot be applied to wear metals of an automatic transmission due to the many variables present that affect concentration limits Wear metal analysis results must be evaluated using a trendline approach A trendline approach plots the concentration level of each wear metal over a period of time A minimum of four data points for each metal is required to establish a trendline A line of best fit drawn through the plotted points is considered a trendline Cause for concern should only occur when significant deviations in the established trendline are present While trendline analysis on wear metals can prove informative and useful a transmission removal decision should not be based solely upon the analysis A removal based solely on wear metal analysis may result in an unnecessary tear down The results should be used in conjunction with other inspection procedures such as functional check road test or fluid sump internal filter inspe
58. nstall the PTO Use only the shims gaskets listed in the MD HD Product Line Parts Catalogs Refer to Service Literature Table 8 1 for the current parts catalog publication numbers for the MD HD Product Line NOTE DO NOT use sealing compounds They are usually incompatible with automatic transmission fluid 54 a Install Gasket Install the special gasket over the guide pins ribbed surface away from the transmission b Mount the PTO 1 Mount the PTO on the guide pins meshing the PTO driven gear with the transmission PTO drive gear 2 Attach the PTO by installing a bolt in the top bolt hole 3 Install the remaining bolts 4 Tighten all bolts to 51 61 Nem 38 45 lb ft c Install Guide Pins The guide pins are included in the PTO manufacturers installation kit 1 Determine the required position of the guide pins in relation to the mounted position of the PTO The guide pins must align with the two blind holes in the PTO pad 2 Install two headless guide pins into the converter housing PTO pad 3 Tighten the pins 4 4 INSTALLING FILL TUBE AND SEAL a Location e HD B 500 fill tube is on the right side e MD B 300 B 400 fill tube may be mounted on either the right or left side The unused fill tube provision must have an expansion plug to fill the tube opening b Installation 1 Install the fill tube seal into the main housing 2 Insert the fill tube through the seal 3 Align the
59. nstructions Refer to Allison Transmission publication number TS2470EN MD HD B Series WTEC II Electronic Controls Troubleshooting Manual for detailed electronic system troubleshooting Road Test Checklist Complete the following checklist Neutral Start Circuit e Starts only in N Neutral Instruments e DO NOT SHIFT light and shift selector display e Transmission fluid pressure gauge if used e Speedometer e Temperature gauge if used Reverse warning system if used Transmission Fluid e Fluid level meets specifications cold neutral level No leaks e Warm up and check fluid level hot neutral level TI No Load Governed Engine Speed No load governed speed of engine e Adjust governor as necessary refer to the manufacturer s specifications for the engine transmission being tested Output Retarder Operation of the output retarder if installed while descending a grade or slowing on a level road if installed e PTO operation Refer to Allison Transmission publication number OM2157EN MD HD B Series WTEC II Electronic Controls Operator s Manual Shift Sequence e Transmission upshifts and downshifts smoothly through all ranges Other Checks e Stall test e Shift quality Comments 78 CUSTOMER SERVICE Section VIII 8 1 OWNER ASSISTANCE There are distributors and dealers around the world ready to stand behind every Allison Transmission product Any
60. nsult the original equipment manufacturer OEM for connection procedure 70 TO COOLER RETURN RETURN COOLER REAR VIEW FRONT VIEW TORQUE ON COOLER FITTINGS 54 68 40 50 LB MD B 300 B 400 OLE Ox 85504 g ui COOLER COOLER RETURN REAR VIEW V07793 01 00 Figure 6 1 Torque Values of Typical Fluid Cooler Line Fittings 71 6 10 CONNECTING ELECTRICAL COMPONENTS NOTE The MD HD Product Line electronic control systems are designed and manufactured to comply with all Federal Communication Commission FCC and other guidelines regarding radio frequency interference electromagnetic interference RFI EMI for transportation electronics Manufacturers assemblers and installers of radio telephone or other two way communication radios have the sole responsibility to correctly install and integrate those devices into MD HD Product Line transmission equipped vehicles to customer satisfaction For further information refer to Allison Transmission publication number TS2470EN MD HD B Series WTEC II Electronic Controls Troubleshooting Manual Remove the cover from the transmission feedthrough connector and carefully connect the transmission external wiring harness Keep dirt and debris out of the connector Connect the external wiring harness a HD B 500 connect engine turbine and output speed
61. on 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 THE 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 A 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 essential to highlight INTRODUCTION 1 1 ABOUT THIS MANUAL This handbook is a
62. or interference with other parts that might chafe or damage the tube Long tubes may require support clips or brackets 9 If equipped with a thermocouple install the thermocouple and connect the leads 10 Install and connect other electrical components such as heaters winterization equipment and pressure sensors 11 If equipped install the pressure gauge tube or line 12 Be sure all unused hydraulic openings are plugged 6 11 FILLING HYDRAULIC SYSTEM e Select a transmission fluid refer to Fluid Recommendations Table 2 5 e Fill the transmission with the required amount of fluid refer to Transmission Fluid And Filter Change Procedure Paragraph c Refill Transmission e Run the engine for about one minute and check the fluid level refer to Transmission Fluid Check Electronic Fluid Check Procedure through Paragraph e Consistency of Readings 6 12 INSTALLATION CHECKLIST Complete the Installation Checklist Refer to Installation Checklist 73 Section VII CHECKS AND ADJUSTMENTS 7 1 INSTALLATION CHECKLIST Use this checklist after transmission installation As items are checked mark them off this list Torque Values All control module bolts tighten to 51 61 Nem 38 44 Ib ft Breather tighten to 12 16 Nem 9 12 lb ft Control module pressure taps tighten to 10 13 Nem 7 10 lb ft Cooler hydraulic fittings tighten to 12 34 47 Nem 25 35 ft 16 54 68 Nem 40 50 Ib ft 20 68 81 N
63. own arrow buttons once For lever shift selector press the DISPLAY MODE DIAGNOSTIC button once e Fluid Level Mode A two minute countdown begins after entering fluid level mode The display flashes and 8 7 1 countdown occurs Fluid level information displays after the countdown if the following conditions have been met Engine is at idle Sump fluid is at operating temperature between 60 104 C 140 220 F Transmission output shaft has stopped Transmission is in Neutral Oil level sensor is functioning properly e Shift Selector Display After two minutes the shift selector will display the fluid level data according to Table 2 1 Fluid Level Shift Selector Display Table 2 1 Fluid Level Shift Selector Display Interpretation of Display OL OK OK Fluid level is correct Fluid level is one quart low or as many quarts as indicated maximum readout is 03 OL HI 01 Fluid level is one quart high or as many as indicated maximum readout is 03 The shift selector can only display two characters at a time One character is displayed under the MONITOR label and one under the SELECT label The fluid information is sequentially displayed according to Table 2 2 Fluid Level Displays Table 2 2 Fluid Level Displays SELECT MONITOR If fluid level is correct L K K If fluid is low If fluid is high 20 NOTE Failure to meet any of the above conditions sto
64. ps the two minutes countdown Refer to Table 2 3 Countdown Interruption Codes for the codes displayed on the shift selector showing the reasons for the countdown interruption When all conditions have been met the countdown will resume where it stopped Table 2 3 Countdown Interruption Codes OL 89 Output shaft rotation OL 95 Sensor failure Engine Output speed Temperature Fluid level If fluid level cannot be checked and a code is issued indicating the reason refer to Table 2 4 Codes Indicating Fluid Level Check Failure Table 2 4 Codes Indicating Fluid Level Check Failure NOTE Report sensor failure to a distributor or dealer Consult the telephone directory or Allison website www allisontransmission com for an Allison Transmission distributor or dealer e Exiting the Fluid Level Display Mode For a pushbutton shift selector press any range selection button For a lever selector press the DISPLAY MODE button once or select a range 21 b 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 WARNING Avoid injury and or prop
65. ring Trouble Codes Using Shift Selector During installation false codes can be recorded in the electronic control memory Clear these codes before road testing the vehicle Use the shift selector to clear the codes Figure 2 5 Shift Selectors e Pushbutton shift selectors enter the diagnostic mode by simultaneously pressing the Up and J Down arrow buttons Simultaneously press the 2 Down arrow buttons twice if oil level sensor is present e Lever selectors enter the diagnostic mode by momentarily pressing the Display Mode button Press the Display Mode button twice if an oil level sensor is present e To clear all active indicators press and hold the MODE button approximately 3 seconds until a tone sounds once e To remove all codes press and hold the MODE button for approximately 10 seconds until the shift selector tone sounds twice d Retrieving Troubleshooting Codes During installation false codes can be recorded in the electronic control memory Clear these codes before road testing the vehicle After road testing the vehicle check for the codes Retrieve the codes by using the shift selector Figure 2 5 Shift Selectors 1 Enter diagnostic mode Paragraph c Clearing Trouble Codes Using Shift Selector 2 The display window will list the code logged position d1 d2 d3 etc then follow with the main code and a sub code This display sequence repeats every two seco
66. ssembly can force the water or cleaning solution into the transmission and contaminate the transmission fluid Seal all openings and the vent assembly breather before spraying steam water or cleaning solutions on the transmission Use care when cleaning the transmission The amount of dust and dirt encountered will determine the frequency of breather cleaning c Replacement Always use a correctly sized wrench to remove or replace the breather Using pliers or a pipe wrench can crush or damage the breather stem and produce metal particles which could enter the transmission Tighten the breather to 12 16 Nem 9 12 lb ft 2 11 TROUBLESHOOTING DO NOT SHIFT Light Figure 2 5 Shift Selectors The DO NOT SHIFT light is usually located on the vehicle s instrument panel 38 Lever shift selector When the light is ON and accompanied by an alarm of eight seconds of short beeps shifts are inhibited by the ECU Pushbutton shift selector When the light is on shifts are inhibited by the ECU The Select digit on the shift selector is blank and no alarm warning sounds e This occurs when the ECU senses abnormal conditions in the transmission e The transmission may continue to operate with inhibited shifting e The ECU will not respond to the shift selector requests Direction changes and shifts to and from N Neutral will not occur e If the lever shift selector is moved while DO NOT SHIFT is indicated a continuous
67. t The following measuring equipment is required 600 mm 24 inches precision caliper e 50 100 mm 2 4 inches telescoping gauge e 25 76 mm 1 3 inches outside micrometer e Dial indicator and mounting attachments base posts and clamps e 0 150 mm 0 6 inches depth micrometer b Flywheel Housing Pilot Bore Diameter The flywheel housing pilot bore diameter must measure MD B 300 400 447 68 447 81 mm 17 625 17 630 inches e HD B 500 511 18 511 30 mm 20 125 20 130 inches c Flywheel Housing Bore Runout Flywheel housing bore total indicated runout TIR cannot exceed 0 51 mm 0 020 inch 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 50 94 50 99 mm 2 006 2 008 inches f Crankshaft Hub Pilot or Adapter Squareness The crankshaft hub or hub adapter cannot be out of square more than 0 13 mm 0 005 inch TIR 58 00 20 6LZL0A NOILVLdVdV WIV19 39VdS H3lH3ANOO NOISSIINNSNVYL V SNH 1 NO HOLVOIONI 79101 WNWIXVIN Ul 6000 ww gro 3NITH31N39 14 5 418002 1 90072 NO 66 06 96 09 VIO 17101 5000
68. t from cooler and disconnect coolant hoses Remove the hoses from the vehicle if they interfere with transmission removal Plug all openings to keep dirt from entering the cooling system 3 2 DISCONNECTING CONTROLS e Disconnect or completely remove controls If controls are not removed from the transmission position them so that they do not interfere with transmission removal e Disconnect the external wiring harness at the feedthrough harness connector Refer to Figure 3 1 or Disconnect the external wiring harness at the earlier models Prevent dirt or moisture from entering a disconnected connector Position the wiring harness so it does not interfere with transmission removal 48 OUTPUT SPEED SENSOR REAR COOLER PORTS FRONT COOLER PORTS OPTIONAL H REAR WITHOUT RETARDER OUTPUT SPEED SENSOR RETARDER TEMPERATURE SENSOR RETARDER CONNECTOR FEEDTHROUGH HARNESS CONNECTOR PTO CONTROLS AND LINES IF NECESSARY NGINE SPEED SENSOR TURBINE SPEED REAR COOLER PORTS SENSOR REAR WITH RETARDER RIGHT SIDE V01445 02 00 Figure 3 1 HD B 500 Disconnect Locations For the MD B 300 B 400 disconnect the engine and output speed sensors Figure 3 2
69. temperature A high temperature condition is indicated by transmission fluid e Discoloration e Strong odor e Fluid analysis The frequency of fluid and filter change is determined by e Local conditions e Severity of operation e Duty cycle Fluid Analysis Transmission protection and fluid change intervals can be optimized by monitoring fluid conditions according to the tests and limits shown in Table 2 8 Fluid Oxidation Measurement Limits Consult the local telephone directory for fluid analysis firms Use only one fluid analysis firm to be sure of consistent and accurate analysis results Refer to Allison Transmission publication number GN2055EN Automatic Transmission Fluid Technician s Guide for additional information Table 2 8 Fluid Oxidation Measurement Limits Test Viscosity 25 percent change from new fluid Total Acid Number TAN 3 0 change from new fluid mg of potassium hydroxide KOH to neutralize a gram of fluid Limits are referenced from an unused fluid sample Collect a new unused fluid sample and submit it for analysis when beginning fluid analysis or repurchasing bulk fluid stock such as a 55 gallon drum or larger Viscosity and total acid number TAN values measured from an unused sample create the baseline against which future used fluid samples will be measured 2 7 TRANSMISSION FLUID CONTAMINATION a Monitoring Contaminant Levels The presence of fluid contaminants in an automatic tra
70. the engine manufacturer or NOTE The engine manufacturer s test data MUST BE available for the equipment dealer or distributor NOTE Allison DOC service tool may be used to perform a stall test or clutch test procedure Refer to Allison Transmission publication number GN3433EN Allison DOC for PC for specific instructions b Stall Test Non Smoke Controlled Engines Perform the following procedures 1 Connect a tachometer Allison DOC service tool can read engine rpm of known accuracy to the engine and install a temperature probe into the converter out to cooler hose 2 Bring the engine to the normal operating temperature WARNING Avoid injury and or property damage caused by unexpected vehicle movement by not starting a stationary stall test until you have taken all of the following actions e Put the transmission in P Park or PB Auto Apply Parking Brake if available or N Neutral e Apply the parking brake and service brake e Chock the vehicle wheels and take any other steps necessary to keep the vehicle from moving e Warn personnel to keep clear of the vehicle and its path 45 3 Shift to any forward range Fourth range is recommended Attain fourth range by using the Allison DOC service tool CAUTION The stall condition causes a rapid rise in fluid temperature never maintain the stall for more than 30 seconds at any one time Do not let the converter out fluid temperature
71. tube bracket with its bolt location 4 Install the fill tube bolt and tighten to 24 29 Nem 18 21 lb ft Refer to Service Literature Table 8 1 for the current parts catalog publication number for the MD HD Product Line On all MD B 300 B 400 Series transmissions install the expansion plug in the unused fill tube hole Tighten the plug to 1 3 Nem 9 26 lb ft 55 4 5 CHECKING PLUGS AND OPENINGS Carefully check all sides and bottom of transmission for loose or missing plugs a Pressure Plugs Check that the 0 4375 20 UNF 2A pressure plugs are tightened to 10 13 Nem 7 10 Ib ft b Fluid Drain Plug Check that the drain plug is tightened to 25 32 Nem 18 24 16 ft c 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 Electro Contact Cleaner cleaner only 4 6 OUTPUT RETARDER ACCUMULATOR INSTALLATION REQUIREMENTS The output retarder accumulator option must be installed as follows Figure 4 1 e Accumulator centerline no higher than top of main housing e Accumulator horizontal to frame or cross member e Maximum hydraulic hose length from transmission to accumulator of 1 8 m 6 ft e Maximum air supply hose length of 12 m 39 ft Pressure protection valve of 586 kPa 85 psig maximum closing pressure installed in air supply hose 56 RETARDER SYSTEM SCHEMATI
72. ure after filling the transmission Table 2 10 Transmission Fluid Capacity 300 B 400 jih 18 19 MD B300 B 400 2 inch 1 12 i 9 1 18 11 37 Approximate quantity does not include external lines and cooler hoses Refer to Figure 2 4 for sump identification 34 2 INCH SUMP Requires filter approximately 102 mm 4 inch in length Approximately 1 75 45 4 INCH SUMP Requires filter approximately 152 mm 6 inch in length Approximately 3 75 inches 7 INCH 3070PT SUMP Requires filter approximately 102 mm 4 inch in length Approximately 7 0 inches VL06095 01 00 Figure 2 4 Sump Identification 35 2 9 FLUID LEAK DIAGNOSIS a Finding the Leak 1 Identify the fluid determining whether it is e Engine fluid e Automatic transmission fluid e Hydraulic fluid from a specific vehicle system 2 Operate the vehicle to reach normal operating temperature and park the vehicle Refer to the following list for possible points of fluid leaks and their causes e Transmission mating surfaces Attaching bolts not correctly aligned Improperly installed or damaged gasket Mounting face damaged e Housing leak Fill pipe or plug seal damaged or missing Filler pipe bracket dislocated Oil cooler connector fittings loose or damaged Output shaft seals worn out or damaged Pressure

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