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Mechanic`s Tips 3000 and 4000 Product Families Allison 4th

1. 91019 09 H LNTO 19 5 SNIGYNL JINGOW HOLNTD ONILV LOY SNISNOH H3183ANOO JINON 5 YALYAANOD 14 6 1 41 0 H3A02 HV3H 7 43409 uvau HOLNTO 90 1 td 21119 92 21119 70 ONISNOH H3ldVQV 99 69 104406 INOH3j 31000 ONISNOH NIYIN ana TO 5 99 FINGOW 5 NIYIN AJINGOW WO LYOddNS LNOYS df3201 JINON H31H3ANOO Figure 1 5 4000 Product Family Cross Section 7 Speed 12 PROVISION INPUT PEED SENSOR SENSOR SSS FEEDTHROUGH HARNESS Q3 B Zag aa CONNECTOR COOLER PORT RUP ul i Z NAMEPLATE NOTE Inch Series Threads 5 3 MAIN PRESSURE NOTE Inch Series Threads RIGHT REAR VIEW BREATH
2. SLNAWSYINOAY NOILVLdVGV 39VdS H3lH3ANOO NOISSINSNVYL g V A NIIN 509 9616 iS NOV f 1074 3NI1H31N39 L3VHSXNVH2 3NI9N3 ONIGVSY WIOL 00 5000 ero 3uog 00 2 9002 Cu 8290 007 ualdvav LIVHSYNVYD NO 66 09 pgs VIG YOLVOIGNI 1 101 NIW 029 2 00 9 500 L0 7 E 40 ynsuod 51108 cue uonisod 10 V MIIA 995 4 ualdvav 13 uone2o 6100 860 Bureq uBis q 80871 26 M H31dVGV 31V1d4X314 NO DNIGVSY 84112 21 WN 62 72 0 anbioy YOLVOIGNI 1101 WAWIXWW 5000 cL 960 X Sz X 8N Gp 8 19 19 0 1108 2 snoueA x X OLIN 9 40 3 uonisod 62 72 0 nbio1 i 563927 leldx l 10 x sz X NS c 8 MIIA 295
3. ch 59 86 WAN 19 19 0 9155 86 WN 19 19 sulBu snoueA X OLIN 9 10 10 ses 1108 X OLN 103 151070 X 4112 11 WN 6z vz 0 g 0 But q L qi 60 96 u N 89 6 OF sunGua x SL X BN z M EU 1108 QV3UHL 31435 U YZ ONN 91 20 21 uaiavav oui in reas etie 5821 gy ze 31V1dX314 01 31V1dX314 41108 ul 0 26661 91296 926 lt gt 14315 Q3N3QHVH HV39 5NIH 4314915 ww 801 F 86105 H3HSVM 7L 22 5 ZILLI 15 avs UL 682 9g lt gt TWOIdAL Ul ZZ 056 68272 5188 5 ualdvav 31V1dX314 ur pzez 0209 pzez 1109 gt ONISNOH 133HMA4 ggug JO 39V3 ONLLNNOW 912 6 ut 7670 55 Figure 5 1 3000 Product Family Engine Adaptation LESEOA 41 99 9 WN 88 51 yoediewod pesn sped apis uoissiusueJ JI oediewod pesn jou sped epis uoissiusue J
4. ualdvav 31V1dX314 01 31V1dX314 578 1 ul 6100 860 5 8 1 02 a 5 payayep Bureq J ur v1 S 0 1708 2 SNISnOH T33HM414 uy inso ipus ufiseq 6 0 56 2 gt VZ ONN 91 6160 110881 Ul 26271 4159 66 19 16 nbi 5 133HMATA e gt 51108 X OLN 40 3273 NILNNOW NIN 1108 12 p M H3HSVAVFZLa 8129 go utu gg gg Figure 5 2 4000 Product Family Engine Adaptation 56 V01717 Figure 5 3 Converter Axial Location Measurement h Flexplate Bolt Hole Flatness Flexplate flatness in the area of the bolt holes is not a measurement required for the 3000 and 4000 Product Family transmissions i Torque Converter Axial Location Using a depth gauge measure from the face of the torque converter housing to the torque converter flexplate adapter mounting face The torque converter axial location should measure 3000 Product Family 49 36 50 38 mm 1 943 1 983 inch e 4000 Product Family 45 54 mm 1 793 inch 5 2 CHECKING FLEXPLATE DRIVE ASSEMBLY a Flexplate Inspection Che
5. OOO SL SAN 000061 5 000 0 sor 000 SETA 000 51 565 5 5 121 pue N d UY so3mbo Ajojeunxoadde your S E IMPON 1017009 pmg Jo 001 jo SULINSSE YIM sorouojsrsuoour pue JOU Surgsnp 519 591195 01551050 1 1 uosry JO osn ATUO pue IMPAS ur 191 000b pesn porddns uorsstursuery uosip y pea ogueuo INPA SAL 10 juoo1ed 001 Sururejuoo uorsstusue uodn poseq pue np uoS aur ALON smoH 0001 SINOH 0001 SINOH 0001 smoH OOS SINOH OOS SINOH OOS SUON 9 SIUC 9 SUON 9 000 000 0f 000 0f 000 00 000 OZ 000 07 SOTA OOO ST SIN 00050 SATIN 00050 SANN 00001 SOMN 0001 000 S67 5 1 PU amp SueA uoN 1914 pue 1 smou 00 s lttu 0006 WA 0008 9q
6. 69 3 the engine for about minute check the fluid level refer to Section 2 3 TRANSMISSION FLUID CHECK Paragraph c Cold Check Procedure 6 12 INSTALLATION CHECKLIST Complete the Installation Checklist Refer to Section 7 70 5 Section ADJUSTMENTS 7 1 INSTALLATION CHECKLIST Use this checklist after transmission installation As items are checked mark them off this list Torque Values control module bolts 51 61 Nem 38 45 Ib ft Speed sensor bolts 24 29 Nem 18 21 Ib ft Hlexplate to crankshaft hub bolts consult engine manufacturer specifications Hlexplate to flexplate adapter bolts 51 61 Nem 38 45 Ib ft Fluid drain plug 25 32 18 24 16 ft Fluid fill tube bracket 24 29 Nem 18 21 Ib ft Control module pressure taps 10 13 Nem 7 10 Ib ft Cooler fittings 12 34 47 Nem 25 35 Ib ft 16 54 68 Nem 40 50 Ib ft 20 68 81 Nem 50 60 ft Cooler port cover bolts 51 61 Nem 38 45 Ib ft Hlexplate adapter to converter cover bolts 24 29 Nem 18 21 Ib ft Output flange bolt 70 80 Nem 52 59 Ib ft PTO cover bolts 51 61 Nem 38 45 Ib ft PTO mounting bolts 51 61 Nem 38 45 Ib ft Breather 12 16 Nem 9 12 lb ft PTO pressure hose to transmission 10 13 Nem 7 10 Ib ft 20 Way transmission feedthrough connector bolt 2 0 3 2 Nem 18 28 Ib inch Rear
7. e 4000 Product Family fill tube is on the right side 52 bolt that is too long may cause cracks and leaks the main housing Refer to the appropriate parts catalog for the correct bolt CAUTION Install the fill tube bracket with the correct length bolt A b Installation Install the fill tube seal into the main housing Insert the fill tube through the seal Align the tube bracket with its bolt location Install the fill tube bolt and tighten to 24 29 Nem 18 21 ft On 3000 Product Family transmissions the unused hole is blocked using a fill tube seal and a new plug Install the fill tube seal into the unused fill tube hole Install the new plug so that the underside of the plug head contacts the fill tube seal 4 5 CHECKING PLUGS AND OPENINGS Carefully check all sides and the bottom of the transmission for loose or missing plugs Pressure Plugs Check that 0 4375 20 UNF 2A pressure plugs are tightened to 10 13 Nem 7 10 lb ft b Fluid Drain Plug Check that the drain plug is tightened to 25 32 Nem 18 24 Ib 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 cleaner only refer to SIL 17 TR 94 53 PREPARING VEHICLE Section FOR TRANSMISSION Errrrri INSTALLATION Sog 5 1 ENGINE TRANSMISSION ADAPTATION REQUIREMENTS Yo
8. 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 5 4 COOLER FILTER AND LINES a Inspection Perform the following and correct any faulty conditions Transmission fluid cooler and related coolant lines Inspect 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 e Hydraulic lines Inspect 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 lube filter after 8000 km 5000 miles Refill the transmission to the correct fluid level refer to Section 2 3 TRANSMISSION FLUID CHECK 59
9. 5 5 CHECKING CONTROLS a Inspection Inspect the following and correct any faulty conditions e Shift selector improper operation poor electrical connections improper harness routing Cab and chassis wiring harness poor electrical connections frayed insulation wiring damage e Throttle sensor components if present freedom of movement improper routing bellows damage improper or loose cable mounting e PTO controls if present damage wear improper operation lubrication electrical harness connections and wiring damage e Temperature gauge capillary tube damage if used sensor damage e Retarder Controls damage wear poor electrical connections frayed insulation wiring damage 60 Fluid pressure gauge tubing damage kinks improper routing b Throttle Position Sensor TPS Adjustment Using Diagnostic Tool When properly installed by the equipment manufacturer the TPS should not require adjustment Confirm that the throttle sensor has been installed to manufacterers specifications refer to Figure 5 6 before adjusting the throttle position sensor The idle position should be approximately 8 9 mm or 0 97 volts or higher and full throttle position should be approximately 35 7 mm or 3 889 volts or lower The TPS is self calibrating meaning there is no optimum closed position or wide open position As l
10. Allison Transmission Allison 4 Generation Controls Mechanic s Tips 3000 and 4000 Product Families MT4015EN 2005 FEBRUARY 1 2005 SEPTEMBER ps 4015 Allison Transmission Allison 4th Generation Controls 3000 Product Family Except 3700 SP 4000 Product Family Allison Transmission Allison Transmission Inc P O Box 894 Indianapolis Indiana 46206 0894 www allisontransmission com Printed in USA Copyright 2007 Allison Transmission Inc 5 TABLE CONTENTS SECTIONI INTRODUCTION 1 1 ABOUT THIS MANUAL Gat Wa Y 7 SECTION PREVENTIVE MAINTENANCE 2 1 PERIODIC INSPECTION AND CARE 18 2 2 IMPORTANCE OF PROPER TRANSMISSION FLUID LEVEL 19 2 3 TRANSMISSION FLUID CHECK 19 2 4 KEEPING FLUID CLEAN 2 25 2 5 FLUID RECOMMENDATIONS 25 2 6 TRANSMISSION FLUID AND FILTER CHANGE INTERVALS 26 2 7 TRANSMISSION FLUID CONTAMINATION 30 2 8 TRANSMISSION FLUID AND FILTER CHANGE PROCEDURE 31 2 9 FLUID LEAK DIAGNOSIS 33 2319 BREATHER ahd sa aw Oh 35 2 11 TROUBLESHOOTING RE q SDE W u QUQ CR HES BS 36 2 12 TRANSMISSION STALL TEST 42 SECTION REMOVING TRANSMIS
11. N N N N M3751EN M3751EN N N N N N N C2150EN Parts Catalog CD ROM CD2150EN CD2456EN O4016EN SM40ISEN SM4014EN 53989 SA2229EN SA2229EN M3752EN OM3752E OM3753E M3349EN OM3349E PC2456EN PO4016EN TS3989EN EA i 4015 200509 www allisontransmission com Printed in USA 200509
12. LEFT V07291 01 00 Figure 1 8 4000 Product Family With PTO Provision RETARDER PTO TOP RIGHT POSITION MOUNTING PADS BOTH SIDES FEEDTHROUGH HARNESS CONNECTOR NAMEPLATE OR ENGINE SPEED SENSOR RIGHT FRONT VIEW MOUNTING PADS BOTH SIDES POSITION MAIN PRESSURE TAP LEFT REAR VIEW 07292 01 00 Figure 1 9 4000 Product Family With Retarder and PTO Provision 16 8 Lo lt lt Qo gt 85 5 5 o o lt P ih zr zm POSITION PTO BOTTOM LEFT MAIN PRESSURE TAP LEFT REAR VIEW z o E a S a 72 e o lt _ of 3 lt POSITION PTO BOTTOM LEFT MAIN PRESSURE TAP REAR VIEW LEFT 07399 01 00 Figure 1 10 4000 Product Family 7 Speed 2 1 PERIODIC INSPECTION AND CARE a Transmission Inspection 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 e Loose bolts transmission and mounting components Fluid leaks repair immediately Loose dirty or improperly adjusted throttle sensor Damaged or loose hoses Worn fraye
13. 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 35 2 11 TROUBLESHOOTING CHECK TRANS Light NOTE Strip pushbutton shift selectors cannot display or clear diagnostic codes The CHECK TRANS light is usually located on the vehicle s instrument panel When the light is ON and the shift selector display is flashing shifts are being inhibited by the TCM This occurs when the TCM senses abnormal conditions in the transmission During this time the digit on the shift selector displays the range in which the transmission is locked The transmission may continue to operate with inhibited shifts The TCM will not respond to shift selector requests Direction changes and shifts to and from neutral will not occur If the ignition is turned OFF and then ON while the CHECK TRANS light is illuminated the transmission will remain in neutral until the diagnostic code is cleared Whenever the CHECK TRANS light is illuminated the TCM logs a diagnostic code in memory The diagnostic codes can be accessed through the shift display or the Allison DOC CHECK TRANS light This occurs when the TCM senses a problem but determines that the problem will not cause immediate transmission damage or dangerous performance NOTE Diagnostic codes be logged without illuminat
14. connect engine turbine and output speed sensors retarder control connector if retarder is present and the retarder temperature sensor 67 COOLER COOLER RETURN TORQUE 54 68 N m 40 50 Ib ft REAR VIEW COOLER RETURN COOLER TORQUE 54 68 40 50 Ib ft FRONT VIEW TO COOLER RETURN TORQUE 68 81 N m 50 60 16 ft REAR VIEW NOTE All torque values apply to cooler fittings NEUE COOLER RETURN TORQUE 54 68 N m 40 50 Ib ft REAR VIEW COOLER TORQUE 34 47 N m 25 35 lb ft FRONT VIEW COOLER TO COOLER RETURN TORQUE 68 81 N m 50 60 Ib ft REAR VIEW V07293 01 00 Figure 6 2 Torque Values of Typical Fluid Cooler Lines For the 3000 Product Family connect the retarder temperature thermistor the output speed sensor and the retarder valve body connector Also the tachograph cable if used to the port on the rear of the retarder housing If used connect the PTO s connector s The PTO connector is NOT part of the Allison Transmission external wiring harness Make sure the speed sensors the PTO connector and other connections are securely seated and latched by pulling on the connector NOT THE WIRES The transmission has a sump fluid temperature sensor on the internal wiring harne
15. Indicates when the DTC has met sufficient criteria to be stored in the long term memory Sufficient criteria may mean the DTC occurred over a specific span of time or over multiple test cycles 37 Check Trans Indicator Indicates when the is requesting the CHECK TRANS light as a result of the DTC Failure Records Indicator Indicates when Failure Records are present Double click on the Y in the Failure Records column to display failure record information Description Provides a brief description of the DTC Double click on the DTC description to link to the specified troubleshooting instructions for the DTC time For example code C1312 is displayed as 41 13 12 Code list position 41 First pair Blank Second pair of characters 13 Third pair of characters 12 Each character pair is displayed for about one second NOTE Diagnostic codes are displayed two characters or digits at a When using the shift selector to retrieve trouble codes if the mode indicator LED is illuminated the displayed code is active If the mode indicator is not illuminated the displayed code is inactive In normal operating mode an illuminated mode indicator signifies secondary mode operation c Clearing Trouble Codes Using Shift Selector NOTE Strip pushbutton shift selectors cannot display or clear diagnostic codes During installation false codes can be recorded in the TCM s memo
16. Table 2 4 Transmission Fluid Operating Temperature Requirements Ambient Temperature Below Which Preheat is Required Viscosity Grade Fahrenheit TranSynd SAE 0W 20 DEXRON IlI saw 2 6 TRANSMISSION FLUID AND FILTER CHANGE INTERVALS a Frequency determined by the severity of transmission service More frequent CAUTION Transmission fluid and filter change frequency is changes can be necessary than recommended in the general guidelines when operating conditions create high levels of contamination or overheating Table 2 5 and Table 2 7 Recommended Fluid Filter Change Intervals is a general guide for fluid and filter change intervals transmission after a standard fluid change combined with the quantity of TranSynd required to fill the transmission to the proper level A mixture of TranSynd or TES 295 equivalent vs TranSynd other than as defined in this paragraph does not meet the requirements that permit the eligibility for the recommendations given in this schedule NOTE Mixture is defined as the quantity of oil remaining in the 26 snoH 0006 smoH 000 0007 0006 SinoH 0006 sinoH 0006 SILO 96 92 spuow sp spuow 96 suo 9c 96 000021 000 021 uni 000 OFZ 000 021 000 021 000 021 STN OOO SL SOT 000 SMN 000061 SeTHA OOO SL SOT 000 SON 0006
17. With PTO Provision Figure 1 1 3000 Product Family Transm 1 1 29 HOLNTO 19 21112 ONILVLOY 5 H31H3ANOO S OH1NOO 19313 310GONW 5 H31H3ANOO JINON 7108105 Ld 27 101519 59 JINGOW 14VHS 43409 wa MEE NNS NNS 21 any01 HOLVIS A ANIGHNL JINON 10 LAVHS JINON 14VHS NIYIN 91019 59 HOLNTD 99 91019 69 SNISNOH LYOddNS 11083 310GOIN 110 1909 05 1NOU3 lon Cross Sect ission Figure 1 2 4000 Product Family Transm 00 0 8220 5 9 1 H LNTO 22 H LNTO 19 FINGOW HOLNID DSNILVLOY 510 1 09 SNISNOH 1 3 H31H3ANOO 310G0l TOH1NO9 TINON SNISNOH H31H3ANOO JTNGOW 1 JINGOW JINGOW NNS NNS 7 13VHS JINGOW 14VHS NIYIN YAdWVO HOLNTS XIGWASSY D
18. maintaining removing or installing 3000 and 4000 Product Family transmissions with Allison 4 Generation Controls 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 appropriate transmission service manual and electronic controls troubleshooting manual Unless specifically indicated otherwise this manual refers to all Allison 4 Generation Controls for 3000 and 4000 Product Family transmissions except for the 3700 SP model The differences between the various transmission models are explained as required 0090 08680A 5 ANIGYNL 91019 29 H91019 310GONW HOLNTO ONILVLOY 3939 SAIC Old 5 YALYSANOD JINON SNISNOH H3183ANOO STOYLNOD O9rinvadAH 081033 JINON 1081105 HOSN3S 13 31 110 JINON Ld JINON 14VHS JINGOW H3A09 HOLVLS NNS 54 1 zd Na 3 LAVHS E x 14VHS a I TINTON H3183ANO2 HOLNO 99 1 19 19 HO1n13 2 ONISNOH 1 1NOHJ 3100 ONISNOH NIYIN TINON 5 1NOHJ lon Cross Sect ission
19. on the vehicle tachometer Install a temperature gauge with the probe in the transmission converter out to cooler line Allison DOC displays sump temperature only Install wheel chocks A driver is in the driver s position The vehicles brakes are fully locked 42 u WARNING To help avoid personal injury such as burns from hot transmission fluid and or to help avoid equipment damage do not stall the torque converter for more than ten seconds maximum and monitor transmission fluid temperature Immediately return the engine to idle if converter out to cooler temperature exceeds 150 C 300 F Operating the transmission at high engine power at transmission stall or near stall conditions causes a rapid rise in the transmission fluid temperature The fluid in the transmission torque converter is absorbing all of the engine power and the vehicle cooling system cannot dissipate the excessive heat load Extended operation under high heat load conditions causes transmission and cooling system damage and can possibly fail hydraulic lines causing leaking high temperature fluid WARNING To help avoid personal injury and equipment damage while conducting a transmission stall test the vehicle must be positively prevented from moving Apply the parking brake the service brake and chock the wheels securely Warn personnel to keep clear of the vehicle and its travel path c Performing a Transmission Stall Test 1
20. 0851 SOMN 00005 SWN 00006 00006 565 SAL n1 5 pue yout IMPON 10002 peu rjug UTE JAT pqnT NOLLVOOA NOLLVOOA 1 OOOH 404 4 4 79 2 29 b Abnormal Conditions Transmission fluid must be changed whenever there is evidence of dirt in the fluid or the fluid is discolored which indicates high temperature condition Fluid analysis will also reveal a high temperature condition Local conditions severity of operation or duty cycle may require more or less frequent fluid or filter changes c Fluid Analysis Transmissions used in high cycle rate applications should use fluid analysis to make sure fluid is changed as soon as needed Transmission protection and fluid change intervals can be optimized by monitoring fluid oxidation according to the tests and limits shown in Table 2 7 Consult your local telephone directory for fluid analysis firms To make sure of consistent and accurate fluid analysis use only one fluid analysis firm Refer to the Technician s Guide for Automatic Transmission Fl
21. After a transmission stall test compare the actual full throttle engine speed at torque converter turbine stall with specifications established by the vehicle manufacturer NOTE Engine speed data can be obtained from the engine manufacturer or from the equipment dealer or distributor Some engine manufacturers provide a programmable parameter to limit engine speed when the transmission output speed is 0 rpm such as at a stop This parameter should be set to a higher value than the expected transmission stall speed before performing the stall test b Stall Testing Preparation If a transmission stall test is to be performed make sure the following preparations have been made before conducting the transmission stall test 1 9 10 11 The manufacturer concurs with performing a full throttle transmission stall test The engine programmable parameter for 0 rpm transmission output speed is set higher than the value expected at transmission stall speed The vehicle 15 an area in which transmission stall test safely performed Make sure the fuel control linkage goes to full throttle and does not stick when released Make sure the engine air induction system and exhaust system have no restrictions Perform a cold check of the transmission fluid level adjust as necessary Connect Allison DOC to the vehicle diagnostic data connector or install an accurate tachometer do not rely
22. ENSION DIMENSION DIMENSION DIMENSION DIMENSION OIL SUMP DESCRIPTION A B c D 2 00 106 7 76 2 66 0 132 6 13 8 4 00 4000 PRODUCT FAMILY A20in 300 2 60in 522 0 54in 101 6 73 7 50 8 86 6 5 9 2 00 3000 PRODUCT FAMILY 400 290in 200in 341in 0 23 in s 101 6 mm 63 5 mm 45 7 mm 86 6 mm 5 9 mm 4 00 in 3000 PRODUCT FAMILY 400 250in 341in 023in 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 Heference drawing AS66 60 Reference drawing AS67 60 Figure 2 1 Standard 3000 and 4000 Product Family Dipstick Markings 24 Consistency of Readings Always check the fluid level at least twice with the engine running Consistency repeatable readings is important to maintaining accuracy of the readings 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 distributor or dealer 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 fi
23. ER TORQUE CONVERTER WITH LOCKUP CLUTCH AND TORSIONAL DAMPER ASSEMBLY PADS BOTH SIDES NOTE Inch Series Threads PTO PROVISION AVAILABLE BOTH SIDES LEFT FRONT VIEW V07289 01 00 Figure 1 6 3000 Product Family With PTO Provision 13 ASSEMBLY PADS BREATHER OUTPUT RETARDER VALVE BODY CONNECTOR SUMP COOLER PROVISION MAIN PRESSURE TAP 4 NOTE Inch Series Threads PROVISION COOLER NOTE Metric Series Threads NOTE Inch Series Threads LEFT REAR VIEW BREATHER ASSEMBLY PADS BOTH SIDE TORQUE CONVERTER WITH LOCKUP CLUTCH OUTPUT AND TORSIONAL DAMPER RETARDER a 9 rz 0 ACCUMULATOR u SY A OIL FILL TUBE AND SZ SU DIPSTICK lt AVAILABLE ON MAIN PRESSURE TAP BOTH SIDES NOTE Inch series threads LEFT FRONT VIEW 07401 01 00 Figure 1 7 3000 Product Family With Retarder 14 e gt TOP RIGHT POSITION PTO PAD FEEDTHROUGH HARNESS CONNECTOR TURBINE SPEED ENGINE SPEED SENSOR SENSOR SENSOR OUTPUT SPEED FEEDTHROUGH FILL TUBE NAMEPLATE eA RIGHT REAR VIEW BOTH SIDES COOLER PORTS MOUNTING PAD KZ 7 LEFT POSITION EN COOLER 5 MAIN PRESSURE
24. GHT SIDE REAR WITH RETARDER V07315 01 00 Figure 3 1 4000 Product Family Disconnect Locations For 4000 Product Family transmissions disconnect the input engine turbine and output speed sensors refer to Figure 3 1 NOTE There may be residual transmission fluid in the retarder accumulator hydraulic line 3 If a retarder is used disconnect the retarder accumulator hydraulic line from the retarder Disconnect any cooling lines Disconnect the wiring harness from the retarder temperature thermistor the output speed sensor and the retarder valve body connector If used disconnect the tachograph cable from the port on the rear of the retarder housing refer to Figure 3 2 4 If a PTO s is used disconnect the PTO s wiring harness 48 ASSEMBLY PADS TACHOGRAPH ENGINE SPEED SENSOR TO COOLER al 5 NAMEPLATE NOTE Inch Series Threads Ad FEEDTHROUGH HARNESS s TEMPERATURE SENSOR SPEED SENSOR NOTE Inch Series Threads 1 07359 01 00 Figure 3 2 3000 Product Family Disconnect Locations 3 3 UNCOUPLING FROM DRIVELINE ENGINE AND VEHICLE Disconnect the vehicle drive shaft from the transmission output flange or yoke Position the disconnected shaft to avoid interference when removing the transmission N If PTO equipped discon
25. LO OL ENGINE SPEED HI OL SELECT N NEUTRAL OL SUMP TEMP LO OL SUMP TEMP HI OL OUTPUT SPEED HI OL CHECK CODES e Exiting the Fluid Level Mode Exit as follows For a pushbutton shift selector press the N Neutral pushbutton once For lever selector press the MODE button once or move the lever For Allison DOC follow directions in the Allison DOC User Guide b Manual Fluid Check Procedure WARNING To help avoid personal injury or property damage caused by sudden and unexpected vehicle movement do not check the fluid level until you 1 Put the transmission in N Neutral 2 Apply the parking brake and emergency brakes and make sure they are properly engaged 3 Chock the wheels and take any other steps necessary to keep the vehicle from moving 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 21 foreign matter the hydraulic system may cause undue wear of transmission parts make valves stick and clog passages Check the fluid level using the following procedure and report any abnormal fluid levels to your service management c 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 above the COLD CHECK band if the transmission fluid is below norma
26. NISNOH 80108 91019 59 JINGOW H31H3ANOO 55 YOLVLS v2 310GONW u3aquviau HOLNTO 69 4 5 LNOYS IMNON 1NOUJ JINON NISNOH NIV lon Cross Sect ission Figure 1 3 4000 Product Family Transm With Retarder 10 00107982 0 5 9 1 HOLNTD 09 91019 12 310GONW 21012 ONILVLOY Old 5 YALYAANOO JINON H3183ANOO IS TOHINOO 2413 JINON 1081 09 31000 Ld 31000N NOLSId 69 JINGOW 14VHS 19110 FINGOW was Ed Ze NNS 5 NNS d 76 5 NIVW 1 19 JINGOW LJVHS NIYIN S Y 1 aes q z nr J HOLVLS l Bana z H91019 55 HOLNTO v2 91019 62 10 NIVM LYOddNS 11083 JINGOW ONISNOH NIVIN TINON TiO LHOddf S LNOYS lon Cross Sect ission With PTO Provision Figure 1 4 4000 Product Family Transm 11 00720717950 310G0l Ld TINON 21 NNS NNS LAVHS TINON 5 NIVIN
27. SION 3 1 3 2 3 3 3 4 3 5 DRAINING TRANSMISSION 47 DISCONNECTING CONTROLS 47 UNCOUPLING FROM DRIVELINE ENGINE AND VEHICLE 49 REMOVING THE TRANSMISSION 50 REMOVING OUTPUT FLANGE OR YOKE 50 SECTION TRANSMISSION PREPARATION 4 1 4 2 4 3 4 4 4 5 CHECKING INPUT COMPONENTS 51 INSTALLING OUTPUT FLANGE OR YOKE 51 INSTALLING adit we 4 52 INSTALLING FILL TUBE AND SEAL 52 CHECKING PLUGS AND OPENINGS 53 SECTION PREPARING VEHICLE TRANSMISSION INSTALLATION 5 1 ENGINE TRANSMISSION ADAPTATION REQUIREMENTS 5 2 CHECKING FLEXPLATE DRIVE ASSEMBLY 5 3 CHASSIS AND DRIVELINE INSPECTION 5 4 COOLER FILTER AND LINES 5 9 CHECKING CONTROLS 42 46 425808454054 tatus SECTION INSTALLING TRANSMISSION INTO VEHICLE Gl HANDLING ee ve Le cee 6 2 MOUNTING TO ENGINE 3466500 esce ve ded 6 3 INSTALLING TRANSMISSION MOUNTING COMPONENTS 6 4 COUPLING TO DRIVELINE 4 233323 Cer o CER x 6 5 CONNECTING OUTPUT RETARDER ACCUMULATOR 6 6 CONNECTING POWER TAKEOFF CONTROLS 6 7 CONNECTING PARKING BRAKE CONTROL 6 8 CONNEC
28. Start the engine While neutral let the transmission warm normal operating temperature Sump temperature 71 93 C 160 200 F Converter out temperature 82 104 180 220 F Perform a hot check of the transmission fluid level and adjust as necessary 3 Turn all engine accessories OFF 5 6 7 Place Allison DOC diagnostic tool in clutch test mode Use the shift selector to select 4 range Using 4 range reduces the torque imposed on the transmission driveline Do not perform a transmission stall test in Reverse CAUTION To help avoid transmission or driveline damage full throttle stall tests must not be performed in R Reverse range all models or low ranges 7 speed models Notify personnel in the area to keep clear of the vehicle Slowly increase engine rpm until engine speed stabilizes Record engine speed 43 CAUTION The transmission stall test procedure causes rapid rise in transmission fluid temperature that can damage the transmission Never maintain a stall condition once engine speed stabilizes or converter out to cooler temperature exceeds 150 C 300 F During a stall condition converter out temperature rises much faster than the internal sump temperature Never use sump fluid temperature to determine the length of the stall condition If the stall test is repeated do not let the engine overheat 8 Record converter out to cooler temperature 9 Redu
29. TING COOLER 6 9 CONNECTING ELECTRICAL COMPONENTS 6 10 CONNECTING SPEEDOMETER DRIVE 6 11 FILLING HYDRAULIC SYSTEM 6 12 INSTALLATION CHECKLIST SECTION VII CHECKS AND ADJUSTMENTS 7 1 INSTALLATION CHECKLIST 7 2 ROAD TEST AND VEHICLE OPERATION CHECKLIST SECTION VIII CUSTOMER SERVICE 8 1 OWNER ASSISTANCE IG uy 8 2 SERVICE LITERATURE TRADEMARK USAGE The following trademarks are the property of the companies indicated e Allison DOC is a trademark of General Motors Corporation e is a registered trademark of the General Motors Corporation e TranSynd is a trademark of Castrol Ltd WARNINGS CAUTIONS NOTES IT IS YOUR RESPONSIBILITY to be completely familiar with the warnings and cautions described in this manual 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 un
30. ations and CONTROLS n is not present on E 3000 8 400 300 installations hos 4 IL V07302 00 01 Figure 6 1 Output Retarder Accumulator Installation NOTE Make sure a pressure protection 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 Connect the hydraulic hose between the retarder and the accumulator Tighten hose fittings to 68 81 Nem 50 60 Ib ft 6 6 CONNECTING POWER TAKEOFF CONTROLS If not already mounted mount the PTO s onto the transmission refer to Section 4 3 INSTALLING PTO 1 Check the PTO harness routing for kinks and sharp bends Avoid routing the cable close to exhaust pipes or manifold The PTO harness must not rub or interfere with adjacent parts 2 Connect controls to the PTO 3 Check for proper PTO control operation 66 CAUTION PTO units using transmission main pressure to engage the PTO gear must have 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 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 th
31. ay 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 2 Start the vehicle check for proper system response during start up a Turn on the vehicle s master ignition switch b The CHECK TRANS light should come on c Start the engine d The CHECK TRANS light should go off e N should appear in the shift selector display 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 4 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 Recheck for Trouble Codes use the Allison DOC the shift selector to determine if codes were set during the road test Refer to Section 2 11 Troubleshooting 7 Troubleshoot if codes exist after the road test problems must be found and corrected refer to TS3989EN Allison 45 Generations Controls Troubleshooting Manual b Service Maintenance Refer the current issue of the 3000 4000 Product Family Service Manuals for detailed transmission service and
32. bolts to 51 61 Nem 38 45 Ib ft 11 Install the flywheel housing access cover if used 6 3 INSTALLING TRANSMISSION MOUNTING COMPONENTS CAUTION Use the type and grade of mounting bolts recommended by ie 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 refer to Figure 6 1 65 RETARDER SYSTEM SCHEMATIC VEHICLE AIR SUPPLY HOSE WIRING HARNESS RETARDER ACCESSORY AND MOUNTING Vo BRACKETS PRESSURE VALVE 85 PSIG MAXIMUM CLOSING i PRESSURE RETARDER sure there is Tie down center NORMALLY orifice fitting on IN CAB of hose if longer CLOSED S000 500 TRANSMISSION than 0 9 m 3 ft i install
33. ce the engine speed to idle and shift the transmission to neutral 10 Raise engine speed to 1200 1500 rpm for 2 minutes to cool transmission fluid 11 At the end of two minutes record converter out to cooler temperature 12 Proceed to the Neutral Cool Down Check Paragraph 2 12 2 d Driving Transmission Stall Test NOTE If the vehicle is equipped with a smoke controlled or an emission controlled engine or engine control programming inhibiting engine acceleration the following stall test procedure can be used WARNING To help avoid personal injury and or equipment damage a driving transmission stall test must be performed by a trained driver and a qualified technician e Driving Transmission Stall Test Preparation If a driving transmission stall test is to be performed make sure the following preparations have been made before conducting the test 1 The manufacturer concurs with performing a full throttle transmission stall test 2 The engine programmable parameter for 0 rpm transmission output speed is set higher than the value expected at transmission stall speed 3 The vehicle is in an area in which the transmission stall test can be safely performed 4 Make sure the fuel control linkage goes to full throttle and does not stick when released 5 Inspect the engine air induction system and exhaust system to make sure there are no restrictions 44 Perform check of the transmis
34. check the fluid level using described TRANSMISSION FLUID CHECK Paragraph b Manual Fluid Check Procedure Table 2 8 Transmission Fluid Capacity x E ERN Approximate quantities do not include external lines and cooler hose For transmissions with add 2 8 liters quarts 2 9 FLUID LEAK DIAGNOSIS a Finding the Leak 1 Identify the fluid Determine whether the fluid is engine oil automatic transmission fluid or hydraulic fluid from a particular vehicle system 2 Operate the vehicle to reach normal operating temperature and park the vehicle Inspect the vehicle to identify the source of the leak Refer to the following list for possible points of transmission fluid leaks and their causes e Transmission mating surfaces Attaching bolts not correctly aligned Improperly installed or damaged gasket Mating surface s damaged e Housing leak Fill tube or plug seal damaged or missing Fill tube bracket dislocated Oil cooler connector fittings loose or damaged Output shaft seals worn out or damaged Pressure 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 33 Converter weld area seal Porous casting e Fluid comes out of fill tube Overfilled incorrect dipsti
35. ck Plugged vent Water or coolant in fluid fluid appears milky Incorrect electronic fluid indication Drain back holes plugged 3 Visually inspect the suspected area Inspect all gasket mating surface for leaks 4 If the leak still cannot be identified clean the suspected area with a degreaser steam or spray solvent Clean and dry the area Operate the vehicle for several miles at varying speeds Inspect the vehicle for leaks If the leak source still cannot be identified use the powder method and or the black light and dye method as explained below b Powder Method 1 Clean the suspected area 2 Apply an aerosol type white powder to the suspected area 3 Operate the vehicle under normal operating conditions 4 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 1 Pour the specified amount of dye into the transmission fill tube 2 Operate the vehicle under normal operating conditions 3 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 the leak
36. ck 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 57 BALL BEARING SEALRING FLEXPLATE I ASSEMBLY FLEXPLATE ae ADAPTER ENGINE X FLYWHEEL HOUSING CRANKSHAFT HUB ADAPTER TRANSMISSION 00533 03 00 Figure 5 4 Arrangement of Adaptation Components NOTE When assembling the flexplate to the crankshaft hub or hub adapter ensure the outer flexplate bolt holes are aligned Flexplate Assembly Installation Install the flexplate onto the engine crankshaft hub using the bolts and torque values specified for that engine Refer to Figure 5 1 or Figure 5 2 for the proper position of an installed flexplate 5 3 CHASSIS AND DRIVELINE INSPECTION Inspect the chassis and driveline components for the following conditions and correct them as appropriate e Transmission mounts broken or worn out e Bolts and other hardwar damaged missing or incorrect Isolators rubber mounts damaged or missing e Driveline angles runout or balance which does not conform to the manufacturer s recommendations e Driveline yoke slip joints freedom of movement damaged or worn out correctly lubricated correctly indexed 58 Driveline midship or hanger bearings damaged misaligned Universal joints
37. cks to see if conditions are right to allow display Certain operating conditions must have been met for a period of two minutes before fluid level is displayed These operating conditions are Engine at idle Sump fluid temperature at 60 104 140 220 Transmission output shaft stopped Transmission in N Neutral Oil level sensor functioning properly measurement be sure sump temperature is in the normal operating range NOTE optimize the accuracy of the electronic fluid level of 71 93 160 200 F If the two minute period has elapsed before the fluid level data request information is displayed immediately However if the two minute period has not elapsed there will be a countdown display before fluid level information displays The countdown display flashes constantly on the monitor digit Countdown starts at 8 and decreases sequentially to 1 during the two minute period When fluid level data is requested and the two minute countdown is in process the flashing display shows the number corresponding to the countdown progress For example if the fluid level data was requested in the middle of the two minute countdown period the display would flash a 5 or a 4 and decrease to 1 e Shift Selector Display Fluid level information is displayed two characters at a time as in Table 2 1 Table 2 1 Fluid Level Shift Selector Display Display Sequence Interpretation of Display oL oK Fluid l
38. cover bolts 90 110 Nem 66 81 Ib ft 7 TPS to transmission bracket M6 bolts 10 13 Nem 84 120 Ib inch 1 20 bolts 12 15 Nem 108 132 Ib inch e Cooler Fluid Lines and Air Hose for No leaks Connection tightnes Correct routing e Throttle sensor for Proper adjustment Correct routing of cable and harness e Driveline for Proper indexing of universal joints Proper drive shaft angles Driveline backlash Lubricated universals and slip joints Hydraulic System for Recommended fluid TranSynd or DEXRONC III Correct fluid level in transmission Dipstick correctly calibrated Refer to Figure 2 1 Fill tube tight Fill tube cap tight Breather clean and free of restrictions No fluid leaks during operation Instruments and Electrical Equipment for Proper wiring and electrical connections Instruments gauges and lights work correctly Shift Selector display is on and CHECK TRANS light is off Fluid temperature gauge Power Takeoff if installed for Controls connected and operative Correctly coupled to driven equipment Lubrication line correctly installed and routed if used 72 7 2 ROAD TEST AND VEHICLE OPERATION CHECKLIST a Driveability NOTE Refer to the latest edition of the 3000 and 4000 Product Family J Operator s Handbooks or Owner s Manuals for operating instructions Refer to Section 8 2 SERVICE LITERATURE for the latest publication number Drive aw
39. d or improperly routed electrical harnesses Worn or damaged electrical connectors Dented worn or out of phase driveline U joints and slip fittings Clogged or dirty breather vent assembly Check transmission fluid for evidence of engine coolant b Vehicle Inspection Check the vehicle cooling system occasionally for evidence of transmission fluid Transmission fluid in the vehicle cooling system indicates a faulty oil cooler c Welding CAUTION When welding on the vehicle DO NOT WELD on the vehicle without disconnecting from the TCM all control system wiring harness connectors e DO NOT WELD on the vehicle without disconnecting TCM battery power and ground leads DO NOT WELD any control components DO NOT CONNECT welding cables to any control components A label describing on vehicle welding precautions ST2067EN 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 2 2 IMPORTANCE 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 the transmis
40. dertaken 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 manual 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 manual is a mechanic s reference for
41. e PTO drivelines for angularity phasing and offsets 6 7 CONNECTING PARKING BRAKE CONTROL 1 Connect and properly adjust the parking brake 2 If present adjust the brake shoe to drum clearance as specified by the manufacturer This does not apply to 4000 Product Family transmissions 6 8 CONNECTING COOLER Refer to Figure 6 2 for typical cooler port locations on the transmission and recommended torque for cooler line fittings 6 9 CONNECTING ELECTRICAL COMPONENTS NOTE Allison Transmission electronic control systems are designed manufactured to comply with all 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 Allison Transmission equipped vehicles to customer satisfaction For further information refer to TS3989EN the Allison 4 Generation Controls Troubleshooting Manual Remove the cover from the transmission feedthrough connector and carefully connect the transmission external wiring harness to the 20 way transmission feedthrough connector Keep dirt and debris out of the connector Tighten the connector bolt to 2 0 3 2 Nem 18 28 Ib inch DO NOT OVER TORQUE Connect the external wiring harness For the 4000 Product Family
42. e available and second number is range attained in selected position Visually check to confirm range selected If display is flashing shift is inhibited V07343 03 01 Figure 2 3 Shift Selector Troubleshooting When No Diagnostic Codes Are Present e Always start with the basics Make sure the shift selector is in the appropriate range Make sure the fluid level is correct Make sure batteries are properly connected and charged Make sure electrical connections are properly made Inspect support equipment for proper installation and operation e If the troubleshooting charts refer you to an Electronic Control check use the diagnostic code troubleshooting information that best applies to the situation e Use the transmission s individual clutch apply circuit pressure taps when necessary 40 f Troubleshooting Intermittent Diagnostic Codes Intermittent codes 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 e Dirty damaged or corroded harness connectors and terminals e Terminals not fully seated in connectors e Damaged harnesses due to poor routing chafing excessive heat tight bends etc Improperly mounted electronic control components Poor connector seals where a
43. evel is correct oL Lo 01 Fluid level is 1 quart low oL HI 01 Fluid level is 1 quart high The shift selector display will also show invalid for display codes two characters at a time An invalid for display code is returned when fluid level data is requested but an operational condition has not been met The invalid for display condition interrupts the two minute countdown momentary increase in engine speed does not affect the countdown The invalid for display codes and their meaning are Table 2 2 Invalid For Display Codes Display Sequence Interpretation of Display 50 Engine low oL 59 Engine rpm too high oL 65 N Neutral not selected oL 70 Sump fluid temperature too low oL 79 Sump fluid temperature too high oL 89 Output shaft rotation oL 95 Sensor failure 20 NOTE Report sensor failure distributor dealer your area Consult the telephone directory for the Allison Transmission distributor or dealer near you The countdown is restarted when the condition causing the invalid for display code is corrected The countdown is not restarted if there is a momentary increase in engine rpm which may generate a code 59 Invalid for display messages are as follows On Allison diagnostic tools Invalid for display messages are shown in the Oil field of the Data Monitor Table 2 3 Invalid for Display Messages DDR Message OL SETTLING TIME X OL ENGINE SPEED
44. ication should be replaced Refer to Service Information Letter 18 TR 98 Rev A d Metal Metal particles in the fluid except for 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 be sure to check the external cooler circuit restriction If circuit pressure drop is above specification the cooler has excessive trapped particles and must be replaced 2 8 TRANSMISSION FLUID AND FILTER CHANGE PROCEDURE a Drain Fluid NOTE Do not drain the transmission if replacing only the filters WARNING Avoid contact with hot fluid or the sump when draining transmission fluid Direct contact with hot fluid or the hot sump may result in bodily injury 1 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 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 Section 2 7 TRANSMISSION FLUID CONTAMINATION Paragraph a Fluid Examination b Replace Filters Refer to Figu
45. ighten bolt to 70 80 Nem 52 59 ft 4 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 appropriate parts catalogs Refer to Table 8 1 for the latest publication number NOTE DO NOT use sealing compounds they are usually incompatible with automatic transmission fluid a Install Guide Pins Guide pins are included in the PTO manufacturers installation 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 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 Mount the PTO on the guide pins meshing the PTO driven gear with the transmission PTO drive gear Retain the PTO by installing a bolt in the top bolt hole Install the remaining bolts Tighten all bolts to 51 61 Nem 38 45 Ib ft 4 4 INSTALLING FILL TUBE AND SEAL a Location 3000 Product Family fill tube may be mounted on either the right or left side The unused fill tube provision must have a plug to fill the tube opening
46. ing part Gaskets Fluid level pressure is too high Plugged vent or drain back holes Improperly tightened fasteners or damaged threads Warped flanges or sealing surfaces 34 Scratches burrs other damage to sealing surfaces Damaged or worn out gasket Cracked or porous casting Improper sealant used where applicable e Seals Fluid level pressure is too high Plugged vent or drain back hole Damaged seal bore Damaged or worn out seal Improper seal 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 The amount of dust and dirt encountered will determine the frequency of breather cleaning Use care when cleaning the transmission SOLUTION DIRECTLY AT THE BREATHER Spraying steam water or cleaning solution at the breather can force water or cleaning solution into the transmission and contaminate the transmission fluid CAUTION DO NOT SPRAY STEAM WATER OR CLEANING c Replacement Always use a correctly sized wrench to remove or replace the breather
47. ing the 36 b Diagnostic Codes Table 2 9 Diagnostic Codes Overview Code List Check Failure Position Active Historic Trans Description Signal Pressure Control Solenoid Stuck Off Engine Speed Input Circuit No Signal TCM Vehicle options Trans ID Error On Shift Selector Y 2 Mode Indicator LED illuminated Accessible only by Allison DOC Diagnostic codes are stored in memory Up to five codes can be stored with the most recent code stored displayed first Diagnostic codes consist of the letter or U followed by four numbers The letter indicates a transmission internal problem while a U indicates problem in a vehicle system or the transmission to vehicle interface The first two digits indicate the type of problem Code List Position shift selector only The position which a code occupies in the code list Positions are displayed as 41 through 45 Code List Position 1 through Code List Position 5 DTC The diagnostic trouble code number referring to the general condition or area of fault detected by the TCM Double click on the numerical code in the DTC column to link to the specific troubleshooting instructions for the DTC Active Indicator Indicates when a diagnostic code is active The MODE indicator LED on the shift selector is illuminated or the diagnostic tool displays Y when the DTC is active Historic Indicator
48. inkages between the engine fuel lever shaft and the attachment point of the throttle sensor CLOSED THROTTLE 183 1 7 21 FULL THROTTLE SAME AS WITHOUT lt 160 2 mm 6 31 in MIN SLIP LINK lt FULLY EXTENDED TN 38 1 mm 1 50 in gt FULLY OPTIONAL THROTTLE SENSOR ASSEMBLY WITH SLIP LINK V00430 06 HITCH PIN CLIP Figure 5 6 Hitch Pin Throttle Position Sensor Installation Diagram INSTALLING Section VI TRANSMISSION INTO VEHICLE 6 1 HANDLING a Preventing Damage Handle the transmission carefully to prevent damage to components in the installation path b Control of Transmission Movements Use a hoist or transmission jack that allows precise control of transmission movements during installation 6 2 MOUNTING ENGINE Use the following to mount the transmission to the engine Reference 1 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 a headless guide bolt into one of the flexplate bolt holes in the flexplate adapter or torque converter mounting lug refer to Figure 5 3 Align the guide bolt with the flexplate hole at the access opening Push the transmission toward the engine while guiding the pilot boss on the to
49. l operating temperatures During operation an overfull transmission can become overheated leading to transmission damage CAUTION The fluid level rises as fluid temperature rises DO NOT fill Park the vehicle on level surface Apply the parking brake and chock the wheels N Run the engine for at least one minute Shift to D Drive then to N Neutral and then to R Reverse to fill the hydraulic system 3 Shift to N Neutral and allow the engine to idle 500 800 rpm 4 With the engine running remove the dipstick from the tube and wipe the dipstick 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 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 d Check Procedure CAUTION When performing the Hot Check procedure the fluid must be at operating temperature to be sure of an accurate check and help prevent transmission damage The fluid level rises as temperature increases During operation an overfu
50. ll transmission can become overheated leading to transmission damage 1 Operate the transmission in D Drive until normal operating temperatures are reached Sump temperature 71 93 160 F 200 F Converter out temperature 82 104 180 F 220 F 22 If the 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 N Park the vehicle on a level surface and shift to N Neutral Apply the parking brake 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 4 Insert the dipstick into the tube until it stops Then remove it Check fluid level reading 5 Repeat the check procedure to verify the reading NOTE Safe operating level is within the HOT RUN band on the dipstick The HOT RUN band is between the HOT FULL and the HOT ADD bands Refer to Figure 2 1 6 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 23 3000 PRODUCT FAMILY 4000 PRODUCT FAMILY 6 35 mm 0 250 REFERENCE lt Blade can be as narrow as 4 76 mm 0 187 in TRANSMISSION CONTROL MODULE SPLIT LINE TRANSMISSION SUMP DIMENSION DIM
51. lling 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 2 5 FLUID RECOMMENDATIONS The hydraulic fluid oil used in the transmission directly affects transmission performance reliability and durability Only a fluid meeting TES 295 or DEXRON III specifications recommended for use in 3000 and 4000 Product Family transmissions TranSynd is a fully synthetic transmission fluid developed by Allison Transmission and Castrol Ltd and is fully qualified to the Allison Transmission TES 295 specifications To make sure a fluid is qualified for use in Allison transmissions check for fluid license or approval numbers on the container or consult the lubricant manufacturer Consult your Allison Transmission dealer or distributor before using other fluid types When choosing the optimum viscosity grade of fluid duty cycle preheat capabilities and or geographical location must be taken into consideration 2 4 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
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54. maintenance instructions Refer to the latest issue of the Allison 4 Generation Controls Troubleshooting Manual for detailed electronic control system troubleshooting Refer to Table 8 1 for the latest publication number 73 Road Test Checklist Complete the following checklist Neutral Start Circuit Starts only N Neutral Instruments CHECK TRANS light and shift selector display Transmission fluid pressure gauge if used Speedometer Temperature gauge if used Reverse warning system if used Transmission Fluid Fluid level meets specifications cold neutral level No leaks 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 Output Retarder Operation of the output retarder if installed while descending a grade or slowing on a level road if installed PTO operation Refer to the appropriate Operator s Manual Refer to Table 8 1 for the latest publication number Shift Sequence Transmission upshifts and downshifts smoothly through all ranges Other Checks Stall test Shift quality Comments 74 CUSTOMER SERVICE Section 8 1 ASSISTANCE There distributors dealers around the world ready to stand behind every Allison Transmission product Any situation that a
55. models 6 Operate the engine at 100 percent full throttle maximum governed speed 7 With the engine at maximum governed speed begin gradually applying the 11 vehicle service breaks while maintaining 100 percent full throttle When the vehicle comes to a complete stop record engine speed Record converter out to cooler temperature Reduce the engine speed to idle and shift the transmission to neutral 10 Raise engine speed to 1200 1500 rpm for two minutes to cool transmission fluid At the end of two minutes record converter out to cooler temperature Proceed to the Neutral Cool Down Check paragraph 2 12 item g 45 g Neutral Cool Down Check Procedure 1 At the end of two minutes the converter out to cooler fluid temperature should return to within normal operating temperature range 2 If the transmission fluid does not cool within two minutes the cause could be a stuck torque converter stator or an issue with the transmission cooler lines or fittings h Transmission Stall Test Results NOTE Environmental conditions such as ambient temperature J altitude engine accessory loss variations etc affect the power input to the converter Due to such conditions stall speed can vary from specification by 150 rpm and still be accepted as within published stall speed e If engine speed with the transmission stalled is more than 150 rpm below the stall speed specification an engine issue is indica
56. nect PTO connections such as a PTO hydraulic hoses b PTO powered equipment drive shaft If transmission mountings support the rear of the engine place a jack other support under the engine 4 Securely support the transmission with a hoist jack or other suitable removal equipment 5 Remove all bolts nuts washers spacers and supports that attach the transmission to the vehicle and the engine 49 3 4 REMOVING THE TRANSMISSION 1 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 2 Raise or lower the transmission as necessary to remove it from the vehicle 3 5 REMOVING OUTPUT FLANGE OR YOKE If replacing the transmission you may need to transfer the output flange or yoke to the replacement transmission Remove the output flange or yoke by removing the M14 x 2 0 x 70 bolt retainer plug and O ring 50 TRANSMISSION PREPARATION Section 4 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 flywheel for damage raised metal that prevents free entry into the crankshaft hub or adapter Sta
57. ntegral cooler is used drain coolant 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 1 Disconnect or completely remove controls If controls are not removed from the transmission position them so that they do not interfere with transmission removal 2 Disconnect the external wiring harness at the feedthrough harness connector Loosen the bolt that retains the 20 way connector to the transmission feedthrough connector Refer to or Figure 3 2 Prevent dirt or moisture from entering a disconnected connector Position the wiring harness so it does not interfere with transmission removal For 3000 Product Family transmissions disconnect the input engine and output speed sensors 47 SPEED SENSOR REAR COOLER PORTS FRONT COOLER PORTS OPTIONAL h REAR WITHOUT RETARDER ACCUMULATOR LINE TACHOGRAPH SPEED PTO CONTROLS SENSOR AND LINES gt IF NECESSARY RETARDER 4 TEMPERATURE SENSOR RETARDER CONNECTOR FEEDTHROUGH a HARNESS TURBINE SPEED 1 5 SENSOR ENGINE SPEED SENSOR REAR COOLER REMOTE COOLER PORTS MANIFOLD RI
58. ong as the travel is within 8 5 35 7 mm range the TPS is set properly A total stroke of 15 2 22 9 mm must be maintained Watch the TPS movements as the controls move it through a full stroke Be 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 refer to Figure 5 5 Error codes occur if the idle position is less than 2 5 mm or when the full throttle position is more than 40 6 mm When idle or wide open throttle positions are in the error zones the TCM will log a code When a TPS code is logged the TCM assumes a default throttle setting which will negatively effect shift quality 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 6 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 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
59. pilot concentricity cannot exceed 0 13 mm 0 005 inch TIR 54 96560 SLNAWAYINDAY NOlLVIdVQOV WIV1D 39VdS H31H3ANOO NOISSIWSNVH L V H31dVGV 14 5 NO SNIQV3H YOLVOIGNI 79101 ut 5000 0 l1JVHSX4NVHO 3NIIH3IN39 L3VHSXNVHO ANION 800 9002 NO 9NIQV3H HO VOIONI 66 05 p6 0S VIG 101 WAWIXVIN 500 p o 9 6 221 0 ualdvav 13 NO NIN 600 82 92 79101 WAWIXYN 10114 6900 09 5000 5 10 5 1108 14 gt I h 31V1dX314 t uonisod 10 Y MIIA 99S y NIN 151070 Buraq 1 episino leldx l reys uBis q 866 1 9 06 1 14 314 NO HOLVOIONI 1 101 50070 gro 1 554221 5 YALYAANOD NIW 1276 H S310H 1N3A 41 12 81 WN 6z vz g6 0 092 x 521 x 1708 01 14 554994 uonisod
60. pplicable e Exposed harness wires EMI generating components and accessories e Loose ground connections To help locate intermittent problems it sometimes helps to place the appropriate tester on the suspect component or circuit and simulate operating conditions wiggle pull bump and bend while watching the tester g Exiting Diagnostic Mode NOTE Strip pushbutton shift selectors cannot display or clear diagnostic codes To exit the diagnostic mode do one of the following Do nothing wait until the calibrated time has passed and the system automatically returns to normal operation Using a pushbutton shift selector simultaneously press the Up and Down arrow buttons e Using a pushbutton shift selector press N Neutral Using shift selector press the MODE button once If using a lever shift selector move the selector lever to any position other than the one it was in when the diagnostic display mode was activated 41 2 12 TRANSMISSION STALL TEST a Purpose Stall testing is performed to determine if a vehicle performance complaint is due to an engine or transmission malfunction Stall testing is a troubleshooting procedure only never perform a stall test as a general check or during routine maintenance Transmission stall speed is the maximum engine rpm attainable when the engine is at full throttle and the torque converter turbine is not moving or stalled
61. re 2 2 1 Remove twelve bolts 1 two filter covers 2 two gaskets 3 two O rings 4 two O rings 5 and two filters 6 from the bottom of the control module 2 When reinstalling parts lubricate and install new O rings 4 and 5 on each cover Lubricate O ring inside filter 6 and push filter onto each cover 2 Install new gaskets 3 on each cover 2 and align bolt holes in gasket with holes in cover 31 3000 PRODUCT FAMILY V03532 02 02 Figure 2 2 Location of Filters for Service 3 Install filter cover assemblies into the filter compartments Align each filter cover assembly with the holes in the bottom of the control module Push the cover assemblies in by hand to seat the seals 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 may cause stripped threads and expensive parts replacement Use a torque wrench to tighten the bolts 4 Install six bolts into each cover assembly and tighten to 51 61 Nem 38 45 ft 5 Replace the drain plug O ring Install the drain plug and tighten to 25 32 Nem 18 25 ft Refill Transmission Refer to Table 2 8 for fluid refill quantities The amount of refill fluid is less than the amount used for the initial fill Fluid remains in the external circuits and transmission cavities after draining the transmission 32 After refill
62. rises in connection with the sale operation or service of your transmission will be handled by the distributor or dealer in your area Refer to the Worldwide Sales and Service Directory SA2229EN for a current listing of Allison Transmission authorized distributors and service dealers 8 2 SERVICE LITERATURE Additional service literature 15 available as shown the following table This service literature provides fully illustrated instructions for the operation maintenance service overhaul and parts support of your transmission To make 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 75 Table 8 1 Available Service Literature 3000 Product 4000 Product Automatic Transmission Fluid Technician s GN2055EN GN2055EN OM3656EN OM3656E Allison DOC For 5 Tool User Guide Operator s Manual Operator s Manual Emergency Vehicle Series Operator s Manual Pupil Transport Shuttle Series Principles of Operation Electronic Troubleshooting Manual Worldwide Sales and Service Directory Also Available On The Internet At www allisontransmission com 76 M3753E OM3749EN OM3749E Operator s Manual Highway Series M3750EN OM3750E O
63. rque converter into the flexplate hub adapter and the guide bolt into the hole on the flexplate 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 Align the bolt holes in the converter housing with those in the engine flywheel housing Install all transmission to engine bolts finger tight 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 64 8 Tighten four bolts at equally spaced intervals around the converter housing bolt circle Use the torque specified by the engine or vehicle manufacturer usually M10 x 1 5 6H bolts tightened to 51 61 Nem 38 45 Ib ft or 7 16 14 bolts tightened to 73 88 Nem 54 65 Ib ft or 16 bolts tightened to 49 58 Nem 36 43 ft 9 Remove the flexplate guide bolt through the engine flywheel housing access opening Replace it with a self locking bolt Tighten the bolt finger tight NOTE DO NOT tighten any flexplate to flexplate adapter bolts until all of the bolts have been installed and tightened finger tight 10 Rotate the engine crankshaft to install the remaining self locking bolts into the flexplate adapter After all bolts have been installed finger tight tighten M8 bolts to 24 29 Nem 18 21 Ib ft and M10
64. rter 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 4 2 INSTALLING OUTPUT FLANGE OR YOKE a Output Oil Seal Check the output oil seal for leaks or damage Refer to the latest edition of the approved Service Manual for replacement instructions If not replacing the oil seal lubricate it with high temperature grease or transmission fluid the flange or yoke Scratches or machine type lead can cause the seal to leak CAUTION DO NOT attempt to polish the oil seal contact surface on b Check Flange or Yoke Check the 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 or yoke after installation to check for binding 51 Install Output Flange or Yoke e 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 T
65. ry Clear these codes before road testing the vehicle Use the shift selector to clear the codes Refer to Figure 2 3 Enter the diagnostic mode on pushbutton selectors by pressing the Up and Down arrow simultaneously Simultaneously press both buttons twice if there is an oil level sensor present With a lever selector enter the diagnostic mode by momentarily pressing the MODE button Press twice if there is an oil level sensor present To clear all active indicators press and hold the MODE button approximately 3 seconds until the mode indicator LED flashes To remove all codes press and hold the MODE button for approximately 10 seconds until the mode indicator LED flashes again 38 d Troubleshooting Codes NOTE Strip pushbutton shift selectors cannot display or clear diagnostic codes After road testing the vehicle check for diagnostic codes Retrieve the codes by using the shift selector refer to Figure 2 3 NOTE Diagnostic codes are displayed two characters or digits at a time For example code C1312 is displayed as 41 13 12 Code list position 41 First pair Blank Second pair of characters 13 Third pair of characters 12 Each character pair is displayed for about one second Enter Diagnostic Mode The display will list the code s logged position 41 42 d3 etc then follow with the code letter designator C P or U the fir
66. sion fluid level adjust necessary Connect Allison DOC to the vehicle diagnostic data connector 8 Install an accurate tachometer do not rely on the vehicle tachometer Install a temperature gauge with the probe in the transmission converter out to cooler hose Allison DOC displays sump temperature only f Performing A Driving Transmission Stall Test 9 N CAUTION The transmission stall test procedure causes a rapid rise in transmission fluid temperature that can damage the transmission Never maintain a stall condition once engine speed stabilizes or converter out to cooler temperature exceeds 150 C 300 F During a stall condition converter out temperature rises much faster than the internal sump temperature Never use sump fluid temperature to determine the length of the stall condition If the stall test is repeated do not let the engine overheat Start the engine While in Neutral let the transmission warm to normal operating temperature a Sump temperature 71 939 160 200 F b Converter out temperature 82 104 C 180 220 F Perform a hot check of the transmission fluid level and adjust as necessary Turn all engine accessories OFF While located in an isolated area begin the driving transmission stall test Select hold range that will limit road speed usually 2 or 314 range Never perform a driving stall test in Reverse or Low range seven speed
67. sion to shift erratically and overheat Fluid may be expelled through the breather or dipstick tube when the fluid level is too high 2 3 TRANSMISSION FLUID CHECK a Electronic Fluid Check Procedure Fluid level be electronically displayed when the transmission contains the optional oil level sensor OLS Fluid level can be displayed on the shift selector or Allison DOC However no oil level sensor diagnostics take place unless the OLS is autodetected by the Allison 4 Generation control system Frequently check for the presence of oil level diagnostics if the transmission is known to contain an OLS If an OLS is not detected during the first 49 engine starts the control system concludes that no OLS is present If an OLS is known to be present but has not been detected then troubleshoot the OLS circuit After the OLS circuit is repaired reset autodetect refer to TS3989EN Allison 4 Generation Controls Troubleshooting Manual for detailed troubleshooting procedures Displaying Fluid Level Information Use the following procedure to display fluid level information For a pushbutton shift selector Simultaneously press the Up and Down arrow buttons once For a lever shift selector Press the DISPLAY MODE button once For the Allison DOC diagnostic tool Refer to the Allison DOC User Guide Fluid Level Display Criteria As soon as fluid level information is requested the TCM che
68. ss A retarder fluid temperature sensor is installed in the retarder on retarder equipped models Actual temperature reading can be made with diagnostic tool Hot fluid conditions in the sump or retarder are read through the diagnostic tool by programming an output function A temperature gauge may be installed in the To Cooler line No temperature gauge installations are available on integral cooler installations If equipped for them install a temperature probe capillary tube and bulb or thermocouple If equipped with a capillary tube and bulb Tightened 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 If equipped with a thermocouple Long tubes may require support clips or brackets Install the thermocouple and connect the leads Install and connect other electrical components such as heaters If equipped install the pressure gauge tube or line Check that all unused hydraulic openings are plugged 6 10 CONNECTING SPEEDOMETER DRIVE The TCM through the VIM provides an electronic speedometer speed signal If used consult the OEM for connection procedures 6 11 FILLING HYDRAULIC SYSTEM 1 Select a transmission fluid refer to Section 2 5 FLUID RECOMMENDATIONS 2 Fill the transmission with the required amount of fluid refer to Table 2 8
69. st two numbers of the code and then the last two numbers of the code this display sequence repeats until the MODE button is pressed again Momentarily press the MODE button to move to the next code stored in memory When the MODE button is pressed after displaying the code in the d5 position the code in the 41 position is displayed NOTE You can also use Allison DOC to clear and retrieve the troubleshooting codes Refer to the Allison DOC for PC Service Tool User Guide for specific instructions 39 HOLD OVERRIDE _ _ HOLD OVERRIDE gt BUTTON BUTTON iur i MODE INDICATOR 0 BUTTON Pa erm SE MODE BUTTON 75 22 MODE ID MODE ID 1 3 DIGITAL DISPLAY DIGITAL DISPLAY DISPLAY DISPLAY MODE SIXSPEED DIAGNOSTIC BUTTON DIAGNOSTIC BUTTON LEFT HAND RIGHT HAND LEVER SELECTOR LEVER SELECTOR WITH REVERSE WITH REVERSE IN REAR TO FRONT 1 DISPLAY 7 6 MODE ID 4 MODE N Ae INDICATOR LED JU u N B Push simultaneously Ason D 9 to enter diagnostic es mode and fluid level check PUSHBUTTON SELECTORS NOTE The first number displayed is highest forward rang
70. ted e If engine stall speed is more than 150 rpm above specification a transmission issue is indicated Conditions that can exist to cause stall speed to 150 rpm above specification could be Transmission fluid cavitation or aeration Verify proper fluid level using the oil level sensor if equipped or dipstick Slipping clutch Torque converter malfunction Sticking or damaged torque converter valve e A low stall speed at least 33 percent lower than published stall speed could indicate an engine issue or a freewheeling stator in the torque converter 46 REMOVING TRANSMISSION 3 1 DRAINING TRANSMISSION Drain the transmission fluid before removing the transmission from the vehicle 1 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 Fluid Examination Reinstall the drain plug 2 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 3 Disconnect all hydraulic lines from the transmission Remove the lines from the vehicle if they interfere with transmission removal Plug all openings to keep dirt from entering the hydraulic system 4 If an i
71. the idle position 3 Check the stroke distance of the throttle sensor from closed to wide open Stroke distance must be from 15 2 22 9 mm 0 60 0 90 inch 61 Adjust so total stroke is within 8 9 mm 35 7 mm band 0 Volt 5 Volts 0 97 volts 3 889 volts 0 278 Volts 4 444 Volts ERROR ERROR ZONE ZONE 0 972 Volts 3 889 Volts l 19 0 75 5 CLOSED THROTTLE WIDE OPEN THROTTLE FULLY a FULLY RETRACTED I EXTENDED ATREST 035in Total Stroke 1 2 5 CT WOT 40 m 0 1 in 1 6 60 0 9 in 0 45 7 xd 1 667 2 500 Volts 05746 00 02 Figure 5 5 Throttle Position Determination Diagram 4 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 5 Design throttle sensor linkage brackets and levers to nominal dimensions so that the system stays within tolerance bands throughout its operating life NOTE The throttle position signal may be provided via communication link on electronically controlled engines 62 BENDING LOAD APPLIED UNACCEPTABLE INSTALLATION MOUNTING PROVISION Use M6 x 1 00 4 20 in series bolts 3 places Torque x 1 00 bolt to 10 13 84 120 Ib in Torque 14 20 in series bolts to 13 14 108 132 Ib in Mount to a solid frame member Flatness of chassis moun
72. ting surface must not exceed 0 8 mm 0 03 in 10 0 MAX INSTALLED OPERATING ANGLE IN ALL DIRECTIONS LOADING IN TENSION ONLY a 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 any time FULLY EXTENDED FORCE REQUIRED 26 7 N 6 0 LB MAX FULLY RETRACTED MOUNTING LENGTH n oti NOTE Mounting length 50 8 mm 2 inches equals cable length 47 5 mm 1 87 in FULL THROTTLE 118 1 mm 4 65 in 4 30 2 mm 1 19 in OPERATING BAND 15 2 22 9 0 6 0 9 in 118 1 mm The location of the clamping bracket relative to the fuel lever at closed throttle must be maintained within this range 95 2 mm 3 75 in Attach to engine or governor 93 45 mm 3 679 in housing using clamp and shims as 87 15 mm 3 431 required Clamp must positively lock in cable groove HITCH PIN CLIP ENGINE FUEL LEVER Fuel lever attachment linkage or bracket must allow fuel lever to return to closed throttle positit when sensor rod is maintained at full throttle p Attach the throttle sensor directly to the engine fuel lever with no breakover or yield l
73. u must make sure a new transmission installation can be adapted to the vehicle s engine The measurements described in this section provide correct transmission to engine adaptation Refer to Figure 5 1 or Figure 5 2 and or 567 020 Typical arrangement of adaptation components is shown in Figure 5 4 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 indicator and mounting attachments base posts and clamps 0 150 mm 0 6 inch depth micrometer b Flywheel Housing Pilot Bore Diameter The flywheel housing pilot bore diameter must measure e 3000 Product Family 447 68 447 81 mm 17 625 17 630 inches 4000 Product Family 511 18 511 30 mm 20 125 20 130 inches 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 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 g Crankshaft Hub Pilot or Adapter Concentricity The crankshaft hub pilot or the hub adapter
74. uid GN2055EN for additional information Table 2 7 Fluid Oxidation Measurement Limits 25 percent change from new fluid Total Acid Number 3 0 change from new fluid 2 percent by volume maximum 2 7 TRANSMISSION FLUID CONTAMINATION a Fluid Examination 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 water 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 Cooler water can also be contaminated by engine oil Be sure to J locate the actual source of cooler water contamination c Engine Coolant Engine coolant in the transmission hydraulic system requires immediate action to prevent malfunction and possible serious transmission damage Completely disassemble inspect and clean the transmission Remove all traces of the coolant and varnish deposits resulting from engine coolant contamination ethylene glycol Any trace of glycol or greater than 0 2 percent water contamination requires complete disassembly and clean up of the transmission and replacement of seals gaskets clutch plates and bearings Solenoid resistance should be measured and 30 checked against the specifications Solenoids not within specif

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