"service manual"
Contents
1. 8 Transmission Fluid and Filter Change Procedure 9 Auxillary Filter s ode se ITE II ER 9 Breather pr i sa pp he eh ee ee 10 Transmission Stall Test and Neutral Cool Down Check 10 REMOVING TRANSMISSION FROM VEHICLE Draining 1 13 Disconnecting Controls 13 Uncoupling From Driveline Engine and Vehicle 14 Removing the 1 14 Removing Input and Output Flanges or Yokes 14 Rebuild Overhaul Instructions 15 PREPARING THE TRANSMISSION FOR INSTALLATION Checking Input Components 16 Installing Output Flange and Input Flange Remote Mounted Transmission 16 Installing PTO us vv rie ieee 17 Installing Transmission Fill Tube and Seal 18 Checking Plugs 18 iii Paragraph SECTION IV 4 1 4 2 4 3 4 4 4 5 4 6 SECTION V 5 1 5 2 5 3 5 4 5 5 5 6 5 7 5 8 5 9 5 10 5 11 5 12 5 13 5 14 SECTION VI 6 1 6 2 SECTION VII 7 1 7 2 Description Page PREPARING VEHICLE FOR TRANSMISSION INSTALLATION Engine Transmission Adaptation Requirements Checking Flexplate Drive Assembly2. 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 catalog of your transmission model NOTE af DO NOT use sealing compounds they are usually incompatible with automatic transmission fluid a Install Guide Pins Included in the PTO Installation Kit Determine the re quired 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 Install two headless guide pins into the converter housing PTO pad Tighten the pins b Determine the Backlash and Proper Gasket Shim You might have a turbine driven PTO or an engine driven PTO For the turbine driven PTO the prescribed backlash between the drive gear in the transmission and the driven gear in the PTO is 0 018 0 024 inch 0 46 0 60 mm prior to S N 32404 and 0 006 0 029 inch 0 16 0 73 mm after S N 32403 models Forthe engine driven PTO the prescribed backlash is 0 006 0 029 inch 0 16 0 73 mm Refer to the latest edition of Service Manual SM2004EN for the description of the method to determine the backlash Establish proper backlash by selecting proper thickness of shims gaskets c Mount the PTO Mount the PTO on the guide
3. inch pipe plugs should be tightened to 48 60 Ib in 5 5 6 7 N m Check the four openings into which the cooler and filter lines connect for cleanliness Remove any closures or obstructions Check the drain plug for tightness The drain plug must be tightened to 15 20 Ib ft 21 27 N m Check the main electrical connector in the transmission housing for cleanliness PREPARING VEHICLE FOR TRANSMISSION IV INSTALLATION 4 1 ENGINE TRANSMISSION ADAPTATION REQUIREM ENTS You must ensure that a new transmission installation can be adapted to the vehicle s engine The explained measurements in this section ensure correct transmission to engine adaptation Refer to Figures 4 1 a Measuring Equipment Refer to the following list for the required measuring equipment 24 0 inches 600 mm precision caliper 2 4 inches 50 100 mm telescoping gauge 1 3 inches 25 76 mm outside micrometer 0 6 inches 0 150 mm depth micrometer Dial indicator and mounting attachments base posts and clamps b Flywheel Housing Pilot Bore Diameter The flywheel housing pilot bore diame ter must measure from 20 125 20 130 inches 511 18 511 30 mm c Flywheel Housing Bore Runout Flywheel housing bore runout cannot exceed 0 020 inch 0 51 mm TIR d Flywheel Housing Face Squareness The flywheel housing face cannot be out of square more than 0 020 inch 0 51 mm TIR e Crankshaft Hub Pilot or Ada
4. Commercial Electronic Control Series Automatic Transmissions All features of the transmission and vehicle involved in installation procedures are discussed The information presented will help the mechanic to remove install and maintain the transmission in a manner that assures satisfactory operation and long service life For additional detailed information refer to HT HTB 700 Electronic Control Series Service Manual SM2004EN or CL B T 700 Series Service Manual SM1314EN and CL B T 755 Electronic Control Series Service Manual Supplement SM1992EN Troubleshooting the electronic control system is presented in Troubleshooting Manual TS2712EN TRADEMARKS USED DEXRON is a registered trademark of General Motor Corporation Loctite is a registered trademark of the Loctite Corporation Teflon is a registered trademark of the DuPont Corporation Pro Link is a registered trademark of Micro Processor Systems Inc FLYWHEEL BOLT ACCESS COVER CONVERTER DRIVEN TO FLTER DS PTO ACCESS COVER CONVERTER 24 REAR COVER HOUSING MOUNTING PAD FROM FILTER PARKING BRAKE MOUNTING PAD OUTPUT SHAFT SPEED SENSOR PICKUP lt TRANSMISSION FLUID DRAIN PLUG H01932 CONNECTOR Model HT 741 748 Transmission Left Rear View TEMPERATURE TRANSMISSION BREATHER TO COOLER J SENSOR PORT MAIN CASE NAMEPLATE ae STARTER __ I RING GEAR REVERSE scu 84 A TASS 12 TORQUE SWITCH PORT i CONVERTE
5. and shims as required Clamp must positively lock in cable groove HITCH PIN CLIP LL 3 431 3 679 IN 87 15 93 44 BELLOWS n ALL il 1 x 0 44 0 66 IN _ 11 2 16 7 mm 0 63 0 86 IN 16 0 21 8 mm CLOSED THROTTLE FULL THROTTLE 1 86 1 88 IN 47 3 47 7 mm N FULLY EXTENDED FULLY RETRACTED V01501 Figure 4 5 Hitch Pin Throttle Sensor Installation Diagram FULLY RETRACTED POSITION ENGINE FUEL LEVER 0 44 0 66 IN 11 2 16 7 SLIP LINK 0 63 0 86 IN 16 0 21 8 mm CLOSED FULL THROTTLE THROTTLE V01500 Figure 4 6 Slip Link Throttle Sensor Installation Diagram 26 INSTALLING SECTION TRANSMISSION V INTO VEHICLE 5 1 HANDLING a Preventing Damage Carefully handle the transmission to prevent damage to components in the installation path b Control of Transmission Movements Use a hoist or transmission jack that al lows precise control of transmission movement during installation 5 2 MOUNTING TO ENGINE Alignone of the flexplate s bolt holes in the flexplate with the access opening at the front of the engine flywheel housing Install a headless guide bolt into one of the flexplate bolt holes in the flywheel Figure 4 1 Align the guide bolt with the flexplate hole at the access opening Lubricate the center pilot boss with molybdenum disulfi
6. any accumulation of grease and dirt Inspect universal joints yokes coupling flanges and slip joint splines for wear or damage Lubricate universal joints and slip joints using the vehicle manufacturer s recommended lubricants NOTE J Misindexing of driveline can cause failure of the transmission FUYWHEEL HOUSING CONVERTER HOUSING STARTER RING GEAR 1 3 554 in 90 27 mm FLEXPLATE ASSEMBLY Sp WEAR PLATE a FLEXPLATE TO ADAPTER BOLT CRANKSHAFT HUB ADAPTER X ADAPTER TO CRANKSHAFT BOLT L01499 01 Figure 4 1 Typical Method Of Coupling Transmission To Engine 20 V01717 Figure 4 2 Converter Axial Location Measurement ENGINE CRANKSHAFT HUB ADAPTER STARTER RING GEAR WEARPLATE FLEXPLATE ASSEMBLY FLEXPLATE ADAPTER TRANSMISSION L02764 Figure 4 3 Arrangement of Adaptation Components 21 4 4 CHASSIS AND DRIVELINE INSPECTION Inspect the chassis and driveline components for the following conditions and correct them as appropriate 4 5 Transmission mounts broken or worn out Bolts and other hardware damaged missing or incorrect Isolators rubber mounts damaged or missing Driveline angles runout balance or offsets which do not conform to the manufacturer s recommendations Driveline
7. by a member of the Regional Service Manager s staff depending on the nature of your problem For prompt assistance please have the following information available Name and location of authorized distributor or dealer Type and make of equipment Transmission model number serial number and assembly number if equipped with electronic controls also provide the ECU assembly number Transmission delivery date and accumulated miles and or hours of operation Nature of problem Chronological summary of unit s history Step Three If you contacted a regional office and you are still not satisfied present the entire matter to the Home Office by writing to the following address or calling the phone number below Manager Warranty Administration PF9 Allison Transmission P O Box 894 Indianapolis Indiana 46206 0894 Phone 317 242 3538 The inclusion of all pertinent information will assist the Home Office in expediting the matter If an additional review by the Home Office of all the facts involved indicates that some further action can be taken the Regional Office will be advised When contacting the Regional or Home Office please keep in mind that ultimately the problem will likely be resolved at the distributorship or dealership utilizing their facilities equipment and personnel Therefore it is suggested the above steps be followed in sequence when experiencing a problem Your purchase of an Allison Tran
8. damage to the transmission Before removing the self locking nut check to see if there are any notches cut into the wrenching flats If there are five notches remove the nut and throw it away If there are less than five notches or none at all remove dirt and burrs from the shaft thread Then loosen the nut until there is about l 16 inch gap between the nut and flange Check the running torque as the nut is being removed The first time the nut is removed no notches running torque must be at least 400 Ib in 45 N m Each additional time the nut is removed one to four notches running torque must be at least 300 Ib in 34 N m Discard the nut if it does not meet the running torque limit 2 6 REBUILD OVERHAUL INSTRUCTIONS Refer to the latest edition of the following Service Manuals for rebuild or overhaul of the transmission HT HTB 700 Electronic Control Series Service Manual SM2004EN CL B T 700 Series Service Manual SM1314EN with CL B T 755 Electronic Control Series Service Manual Supplement SM1992EN SECTION PREPARING THE III TRANSMISSION FOR INSTALLATION 3 1 CHECKING INPUT COMPONENTS a Bolt Holes Check all bolt holes on the front of the flywheel converter flexplate adapter The threads must be undamaged and the holes must be free of any chips or foreign materials b Pilot Boss Check the pilot boss at center of flywheel for damage or raised metal which could prevent bolt free entry
9. drop must not exceed 30 psi 206 kPa at 15 gpm 57 liters minute at operating temperature and full throttle stall Install the auxiliary filter 5 12 CONNECTING SPEEDOM ETER DRIVE NOTE J An electronic speed signal is provided by the ECU to operate an electronic speedometer The mechanical speedometer driven gear assembly is required only if the vehicle is equipped with a mechanical speedometer 30 TIGHTEN FITTINGS TO 40 50 LB FT 54 68 Nem FROM COOLER AUXILIARY FILTER RECOMMENDED AFTER DEBRIS CAUSING FAILURE VIEW A TRANSMISSIONS WITHOUT RETARDER TIGHTEN FITTINGS TO 40 50 LB FT 54 68 Nem TO FILTER VIEW B TRANSMISSIONS WITH INPUT RETARDER TIGHTEN FITTINGS TO 40 50 LB FT 54 68 Nem FILTER FROM COOLER VIEW C TRANSMISSIONS WITH OUTPUT RETARDER L02543 Figure 5 1 Torque Values of Typical Filter and Cooler Lines 31 Install the speedometer driven gear assembly into the transmission if required Tighten the gear assembly in the transmission rear cover to 45 50 Ib ft 62 67 N m If no speedometer drive is provided be sure the plug is installed to close the hole in the housing torque is same as for gear assembly Install the speedometer drive cable onto the driven gear assembly Tighten the nut to 52 Ib inch 6 N m Avoid kinks or sharp bends in the cable assembly Bends must have a minimum radius of 6 inches 150 mm No more than one 90 bend i
10. fluid cools properly refer to Troubleshooting Manual TS2712EN 12 REMOVING S TRANSMISSION pag FROM VEHICLE 2 1 DRAINING TRANSMISSION Drain the transmission fluid before the transmission is removed from the vehicle Remove the drain plug from the oil pan Examine the drained transmission fluid for evidence of contamination see Section 15 Reinstall the drain plug Remove transmission fluid fill tube if it interferes with transmission removal NOTE J A significant amount of transmission fluid may drain from the hydraulic lines when they are disconnected from the transmission Disconnect all other hydraulic lines from the transmission Remove the lines from the vehicle if they will interfere with the transmission removal Plug all hose openings to keep dirt from entering the hydraulic system 2 2 DISCONNECTING CONTROLS Disconnect or completely remove the electronic controls If controls are not removed from the transmission position them so they do not interfere with transmission removal e Disconnect the electronic control chassis harness from the transmission main connector and from the speed sensor connector Figure 2 1 fan external pressure switch for a reverse signal is used disconnect vehicle harness from switch Disconnect the speedometer drive cable if used Disconnect the air supply line at the output retarder control valve if output retarder is used Disconnect the inp
11. immediately after the engine speed has been recorded in the stall test Record the converter out temperature With the transmission remaining in Neutral run the engine at 1200 1500 rpm for two minutes to cool the transmission fluid Atthe end of two minutes record the converter out temperature d Results NOTE Environmental conditions such as ambient temperature altitude engine accessory loss variations etc affect the power input to the converter Under such conditions a stall speed deviation within 150 rpm of specification can be accepted as within normal range If engine stall speed is more than 150 rpm below the stall speed specified by the engine manufacturer an engine problem is indicated such as need for tune up If engine stall speed is more than 150 rpm above specification a transmission problem is indicated such as slipping clutches cavitation or torque converter failure Refer to or the applicable service manual number An extremely low stall speed such as 33 percent of the specified engine stall rpm during which the engine does not smoke could indicate a freewheeling stator If the engine stall speed conforms to specification but the transmission fluid overheats refer to the cool down check If the transmission fluid does not cool during the two minute cool down check a stuck stator can be indicated If the engine stall speed conforms to specification and the cool down check shows that transmission
12. pins meshing the PTO driven gear with the PTO drive gear Retain the PTO by installing a bolt in the top bolt hole Install the remaining bolts Tighten the bolts to 51 61 N m 38 45 Ib ft CAUTION PTO units using transmission main pressure to engage the PTO driven gear must have a positive main pressure shut off at the solenoid valve when the PTO is not engaged 3 4 INSTALLING TRANSMISSION FILL TUBE AND SEAL a Inspection Inspect the fill tube for proper vent location and vent hole diameter a vent hole should be located on the underside of the tube and just below the seal of the dipstick and the diameter should measure 0 060 0 080 inch 1 6 2 0 mm b Location The filler tube may be mounted on either the left or the right side The unused fill tube provision must have an expansion plug installed in the fill tube opening CAUTION Install the fill tube brackets with the correct length bolt Too long a bolt may cause cracks and leaks in the main housing Refer to the appropriate HTB 700 Series Parts Catalog PC1965EN or CLT 700 Series Parts Catalog PC1993EN c Installation Install the fill tube into the main housing Insert the fill tube through the seal Align the tube bracket with its bolt location Install the fill tube bolts and tighten to 14 18 Ib ft 19 24 N m 3 5 CHECKING PLUGS OPENINGS Check carefully at all sides of the transmission for loose or missing hydraulic pressure check plugs The
13. 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 J A note is used when an operating procedure practice etc is essential to highlight Paragraph SECTION 1 1 1 2 1 3 1 4 1 5 1 6 1 7 1 8 1 9 1 10 1 11 1 12 1 13 SECTION II 2 1 2 2 2 3 2 4 2 5 2 6 SECTION III TABLE OF CONTENTS Description Page PREVENTIVE MAINTENANCE Periodic Inspection and 1 Importance of Proper Transmission Fluid Level 1 Transmission Fluid Check Procedures 2 Keeping Transmission Fluid Clean 5 Automatic Transmission Fluid Recommendations 5 Transmission Fluid and Filter Change Intervals 6 Fluid Temperatures 7 High Efficiency Main Pressure External Filter Change 8 Transmission Fluid Contamination
14. 55 N m Install the flywheel housing access cover 5 3 INSTALLING TRANSMISSION MOUNTING COMPONENTS Install all bolts washers spacers isolators brackets and supports required to support the transmission in the vehicle frame CAUTION Use the type and grade of mounting bolts recommended by the vehicle manufacturer Tighten the bolts to the torque recommended by the vehicle manufacturer 5 4 COUPLING TO DRIVELINE Couple the driveline companion flange or universal joint yoke to the flange or yoke on the transmission Use the bolts and torque recommended by the vehicle manufacturer Check the universal joint angularity all joints in driveline to determine if they are within the specifications of the vehicle manufacturer 5 5 COUPLING TO ENGINE REM OTE M OUNTED TRANSMISSION Install if removed the input drive shaft components that connect the engine and transmission Couple the flange or yoke to the flange or yoke at the front of the transmission Use the bolts and torque recommended by the vehicle manufacturer Check the transmission to engine alignment against the vehicle manufacturer s specifications 28 5 6 CONNECTING INPUT RETARDER CONTROL Place the operator s control at the OFF disengaged position Check the input retarder control valve The valve is spring loaded to retract into the valve body when the retarder is OFF Lift the valve upward to the ON position to check for the
15. Checking Input Drive Components Remote Mounted Transmissions Chassis and Driveline Cooler Filter and Lines Checking Controls 0 0 0 eene INSTALLING TRANSMISSION INTO VEHICLE be rre Re es Mounting to Installing Transmission Mounting Components Coupling to Coupling to Engine Remote Mounted Transmission Connecting Input Retarder Control Connecting Output Retarder 1 Connecting Power Takeoff Controls Connecting Parking Brake Control Connecting Cooler Installing Auxiliary Connecting Speedometer Installing Temperature and Pressure Sensors Connecting Electrical Components Filling the Hydraulic CHECKS AND ADJUSTM ENTS Installation wasa qa ana Road Test and Vehicle Operation Checklist CUSTOMER SERVICE Owner Assistance 2 y sse Service Literature ccce Re PREFACE This handbook is a mechanic s reference for removing installing and maintaining the HT HTB CL B T 700
16. IFT light should come on Start the engine The DO NOT SHIFT light should go off Clear Trouble Codes during installation it is common for false codes to be stored in the electronic control s ECU These codes must be cleared prior to road testing the vehicle Road Test the Vehicle allow the electronic control time to converge shifts Check for Proper Operation check all components for proper mounting and operation and check for transmission fluid leaks at gasket surfaces lines and hoses Re check for Trouble Codes use the Pro Link or Diagnostic Data Reader DDR to determine if codes were set during the road test Connect the Pro Link or DDR to the ECU through the Diagnostic Data Link DDL Troubleshoot if codes exist after the road test problems must be found and corrected Refer to the latest edition of HT CT Troubleshooting Manual TS2712EN b Service and Maintenance Refer to the latest edition of the HT 700 Series Electronic Control Service Manual for detailed transmission service and mainte nance instructions Refer to the latest edition of the HT 700 Series Electronic Control Troubleshooting Manual for detailed electronic control system trouble shooting Refer to Section 7 2 or the latest publication number 35 Road Test Checklist Complete the following checklist Neutral Start Circuit Starts only in neutral Instruments DO NOT SHIFT light and CHECK TRANS
17. ING SOLUTION DIRECTLY AT THE BREATHER Spraying steam water or cleaning solution directly at the breather can force the water or cleaning solution into the transmission c Replacement Always use a wrench of the proper size to remove or replace the breather Pliers or a pipe wrench can crush or damage the stem and produce metal chips which could enter the transmission Tighten the breather to 9 12 Ib ft 12 16 N m 1 13 TRANSMISSION STALL TEST AND NEUTRAL COOL DOWN CHECK WARNING When conducting a transmission stall test the vehicle must be prevented from moving Apply the parking brake and service brakes and block the vehicle securely Warn personnel to keep clear of the vehicle and its travel path Failure to do so can cause serious injury a Purpose The stall test provides a method for determining if the malfunction is in the engine or in the transmission when a vehicle is not performing satisfactorily The neutral cool down check utilizes the two minute cooling period on the stall test to gather transmission fluid temperature data for troubleshooting reference b Transmission Stall Test Procedure The engine stall point rpm under load is compared to the engine manufacturer s specified rpm for the stall test NOTE The engine manufacturer s test data must be available for the stall test This data can be obtained from the engine manufacturer or from your equipment dealer or distributor Connect a tach
18. Mechanic s Tips HT HTB CLT CLBT 700 Series Electronic Control Transmissions MT1958EN MT1958EN Mechanic s Tips Allison Transmission HT HTB CLT CLBT 700 Series Allison Transmission March 1995 Division of General Motors Corporation Box 8 ianapolis India 94 Indi na 46206 0894 Revision 1 1999 April Printed in U S A Copyright 1995 General Motors Corp WARNINGS CAUTIONS AND NOTES IT IS YOUR RESPONSIBILITY to be completely familiar with the warnings and cautions described in this handbook It is however important to understand that these warnings and cautions are not exhaustive Allison Transmission could not possibly know evaluate and advise the service trade of all conceivable ways in which service might be done or of the possible hazardous consequences of each way Consequently Allison Transmission has not undertaken any such broad evaluation Accordingly ANYONE WHO USES A SERVICE PROCEDURE OR TOOL WHICH IS NOT RECOMMENDED BY ALLISON TRANSMISSION 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 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
19. NG GEAR SENSOR PORT NAMEPLATE m AB v TORQUE S CONVERTER REVERSE SIGNAL PORT eo PREHEAT PROVISION TRANSMISSION FILLER TUBE PROVISION CONVERTER HOUSING MOUNTING PAD TO COOLER FROM COOLER H01937 INPUT RETARDER VALVE BODY Model HT 755DR Transmission Right Front View With Input Retarder viii CONVERTER TO FILTER PTO ACCESS COVER HOUSING FLYWHEEL N ADAPTER HOUSING GOVERNOR COVER STARTER RING GEAR BULKHEAD FROM FILTER CONNECTOR H01938 Model HTB 748 Transmission Left Front View With Output Retarder RETARDER PISTON RETARDER CONTROL AIR PRESSURE ADAPTER APPLY LINE FROM COOLER ENSOR SENSO R X TO COOLER RETARDER CONVERTER OUT HOUSING haki LuBe PORT ACCUMULATOR A FROM COOLER i ft NAMEPLATE TO COOLER na TRANSMISSION FLUID 2 FILLER TUBE PROVISION TEMPERATURE PROBE PROVISION H01939 RETARDER VALVE om REGULATOR VALVE d Model HTB 748 Transmission Right Rear View With Output Retarder ix CONVERTER CONVERTER DRIVEN PTO ACCESS COVER ACCESS COVER is MAIN HOUSING MOUNTING PAD CONVERTER INPUT DRIVE OUTPUT FLANGE NUT SPEED SENSOR PICKUP INPUT RETARDER BULKHEAD FROM FILTER CONNECTOR 81 2 in CASTIRON OIL PAN H01940 Model CLBT 755 Transmission Left Front View TRANSMISSION MAIN CASE INPUT RETARDER VALVE BOD
20. R PREHEAT PROVISION TRANSMISSION FLUID FILLER TUBE PROVISION CONVERTER HOUSING MOUNTING PAD FROM COOLER wits Model HT 741 748 Transmission Right Front View vi CONVERTER DRIVEN PTO ACCESS COVER ADAPTER HOUSING REAR COVER MOUNTING PAD PARKING BRAKE MOUNTING PAD FLYWHEEL BOLT ACCESS e NE TO FILTER CONVERTER HOUSING p FROM FILTER Ga F OUTPUT SHAFT SPEED SENSOR CONNECTOR FICKUR FLUID DRAIN PLUG H01934 Model HT 755CR Transmission Left Rear View BREATHER TO COOLER TEMPERATURE SENSOR PORT TRANSMISSION MAIN CASE NAMEPLATE STARTER RING GEAR m1 TORQUE REVERSE SIGNAL 4 CONVERTER PREHEAT PROVISION TRANSMISSION FLUID 7 FILLER TUBE PROVISION CONVERTER HOUSING MOUNTING PAD FROM COOLER H01935 Model HT 755CR Transmission Right Front View vii ENGINE DRIVEN TOP INPUT RETARDER BRAKE OPTION PTO ACCESS COVER CONVERTER DRIVEN PTO ACCESS COVER TO FILTER P NUS REAR COVER a lt MOUNTING PAD CONVERTER gy HOUSING E PARKING BRAKE MOUNTING PAD OUTPUT SHAFT ENGINE DRIVEN LEFT SIDE PTO SPEED SENSOR ACCESS COVER m PICKUP TRANSMISSION FLUID DRAIN PLUG CONNECTOR ADAPTER HOUSING H01936 Model HT 755DR Transmission Left Rear View With Input Retarder TRANSMISSION MAIN CASE TEMPERATURE STARTER RI
21. UID LEVEL Because the transmission fluid cools lubricates and transmits hydraulic power it is important that the proper fluid level be maintained at all times If the fluid level is too low the torque converter and clutches will not receive an adequate supply of transmission fluid and the transmission will overheat If the fluid level is too high the fluid aerates causing the transmission to shift erratically and overheat Fluid may be expelled through the breather or dipstick tube when the fluid level is too high 1 A severely low fluid level causes the Allison Transmission Electronic Control to do two things automatically Turn on the CHECK TRANS light Prevent upshifting into the highest range When the fluid level is corrected the transmission will return to normal operation Do not use the Electronic Control to replace regular fluid level checks Check the level at the intervals specified in your vehicle service instructions 1 3 TRANSMISSION FLUID CHECK PROCEDURES WARNING Take the following precautions so that unexpected possible sudden vehicle movement is avoided Whenever it becomes necessary to leave the vehicle even momentarily while the engine is running place the transmission shift selector in Neutral set the park ing brake and or emergency brakes and chock the wheels a Fluid Check Procedure Clean all dirt from around the end of the fill tube before removing the dipstick Do not allow
22. Y BREATHER NAMEPLATE NS FRONT MOUNTING REVERSE SIGNAL TRUNNION PORT TEMPERATURE TO COOLER SENSOR PORT FROM COOLER H01941 Model CLBT 755 Transmission Right Front View PREVENTIVE SECTION MAINTENANCE I 1 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 linkage damaged or loose hoses worn frayed or improperly routed electrical harnesses worn or out of phase driveline U joints and slip fittings CAUTION When welding on the vehicle DO NOT WELD on the vehicle without disconnecting from the ECU all control system wiring harness connectors 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 A label describing on vehicle welding precautions is available from your authorized Allison service dealer and should be installed in a conspicuous place A vehicle used in a vocation that requires frequent modifications or repairs involving welding must have an on vehicle welding label 1 2 IMPORTANCE OF PROPER TRANSMISSION FL
23. at the PTO control valve when not in use Couple the PTO output to its driven equipment Check couplings or universal joints for proper assembly and alignment 29 5 9 CONNECTING PARKING BRAKE CONTROL Connect and properly adjust the parking brake linkage Adjust the brake shoe to drum clearance as specified by the manufacturer 5 10 CONNECTING COOLER FILTER Figure 5 1 shows typical cooler and filter line locations Be sure that the hydraulic lines are of the proper size and type recommended Use new O ring seals where required Secure the filler tube bracket s as required Connect the hydraulic lines to the transmission and to the cooler and external filter checking to see that the lines are clean and unobstructed Tighten the line fittings at the transmission to the torque values shown on Figure 5 1 Check for sharp bends kinks twists and for contact with components that will chafe or collapse the oil lines Check to ensure that the hydraulic lines are not in close proximity to manifolds or exhaust pipes Excessive heat will hasten the deterioration of hydraulic lines 5 11 INSTALLING AUXILIARY FILTER Itis recommended that an auxiliary filter be installed in the cooler circuit following cleanup The auxiliary filter must have a 40 micron max filter element and a maximum filter pressure drop of 2 psi 13 kPa at 15 gpm 57 liters minute at 180 F 82 C The maximum cooler circuit pressure
24. de grease Push the transmission toward the engine while guiding the pilot boss on the flywheel into the flexplate hub adapter and the guide bolt into the hole in 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 of the bolts finger tight that retain the transmission to the engine CAUTION The converter housing must be flush against the engine flywheel housing before tightening any bolts Do not use the bolts to seat the housing Tighten four bolts at 90 degree intervals around the converter housing bolt circle Then tighten the remaining bolts Use the torque recommended by the vehicle or engine manufacturer 27 Remove the guide bolt through the access opening in the engine flywheel housing Replace it with a 2 20 x 1 inch self locking bolt Tighten the bolt finger tight at this time NOTE J Do not tighten any flywheel bolts until all of the bolts have been installed and tightened finger tight Rotate the engine drive shaft enough to install the eleven remaining V2 20 x 1 inch self locking bolts into the flywheel finger tight When all bolts including twelve 1 2 20 x 34 inch self locking bolts are in place tighten them to 96 115 Ib ft 131 1
25. e of your transmission will be handled by the distributor or dealer in your area check the telephone directory for the Allison Transmission service outlet nearest you Reference the Sales and Service Directory SA2229EN for the current listing of Allison Transmission authorized distributor and service dealers We recognize however that despite the best intentions of everyone concerned misunderstandings may occur To further assure your complete satisfaction we have developed the following three step procedure to be followed in the event a problem has not been handled satisfactorily Step One Discuss the problem with a member of management from the distributorship or dealership Frequently complaints are the result of a breakdown in communication and can quickly be resolved by a member of management If you have already discussed the problem with the Sales or Service Manager contact the General Manager All ATD dealers are associated with an ATD distributor If the problem originates with a dealer explain the matter to a management member of the distributorship with whom the dealer has his service agreement The dealer will provide his ATD distributor s name address and telephone number on request 37 Step Two When it appears the problem cannot be resolved readily at the distributor level without additional assistance contact the Allison Transmission Regional Office responsible for the local distributor You will be assisted
26. f coolant and varnish deposits resulting from coolant contamination Replace all seals gaskets and friction faced clutch plates Repair or replace the cooler prior to installation of the new or rebuilt transmission 1 10 TRANSMISSION FLUID AND FILTER CHANGE PROCEDURE NOTE J Do not drain the transmission fluid if only filters are being replaced a Drain Fluid Drain the fluid when the transmission is at operating temperature 160 200 F 71 93 C Hot fluid flows quicker and drains thoroughly Remove the drain plug from the oil pan and allow the fluid to drain into a suitable container Examine the fluid as described in the Section 1 8 b Replace Filters Refer to the latest edition of the HT 700 Series Service Manual SM2004EN for complete procedures for replacement of the filter Remove the oil pan and replace the old filter with the new one c Refill Transmission The amount of refill fluid is less than the amount used for the initial fill Fluid remains in the external circuits and transmission cavities after draining the transmission After refill check the fluid level using the procedure described i 1 11 AUXILIARY FILTER Ifa condition occurs that introduces debris into the transmission hydraulic system a complete cleanup of the cooler and lines is required Because repeated cleaning and flushing may not remove all debris install an auxiliary filter in the cooler out circuit models without an
27. full travel of 1 5 inches 38 mm from OFF to ON position Release the valve permitting the spring to retract the valve Be sure the valve is fully retracted Adjust the linkage so that rod end or clevis registers with the pin hole in the retarder valve Connect the linkage to the retarder valve and check the operation of the valve The valve must be fully extended when the operator s control is at ON The valve must be fully retracted when the control is at OFF NOTE J Failure to ensure a full off stroke will result in low vehicle power and transmission overheating Failure to ensure a full on stroke will result in less than rated retarder performance 5 7 CONNECTING OUTPUT RETARDER CONTROL The output retarder when used is connected to the vehicle braking system by an air supply line Connect the air supply hose fitting to the retarder control valve Tighten the fitting to 7 10 Ib ft 10 13 N m 5 8 CONNECTING POWER TAKEOFF CONTROLS f not previously installed mount the PTO on the transmission Refer to Paragraph 3 3 for instructions Connect controls to the PTO Check for proper operation of the controls Check cable or linkage rod routing Kinks sharp bends and close proximity of the cable to exhaust pipes or manifold must be avoided Rods or linkage must not rub or interfere with adjacent parts CAUTION PTOs using main transmission oil pressure to apply the PTO must have main pressure dead headed
28. he HOT RUN band d Consistency of Readings Always check the fluid level at least twice and with the engine running Consistency is important to maintain accuracy of the reading If inconsistent reading persists check the transmission breather to be sure it is clean and unclogged OIL PAN SPLIT LINE A B D Y HT CT DIM DIM DIM DIM PAN SIZE A B c D 4 50 25 4 38 1 50 8 mm 44 5 mm i 1 00 IN 1 501N 2 001 1 75 IN 6 00 38 1 mm 63 5 mm 95 3 mm 76 2 mm 1 50 IN 2 501N 3 751N 3 00 IN 63 5 mm 88 9 mm 120 7 mm 7 00 2501N 3 501 4 75 IN N A 63 5 mm 88 9 mm 120 7 mm 8 50 2501N 3501N 4 75 IN N A Approximate Dimension OEM Customer is to establish COLD RUN BAND at installation V01889 Figure 1 1 Typical Dipstick Markings 1 4 KEEPING TRANSMISSION FLUID CLEAN CAUTION Containers or fillers that have been used for any anti freeze or engine coolant solution must not be used for the transmis sion fluid Antifreeze and coolant solutions contain ethylene glycol which if introduced into the transmission can cause the clutch plates to fail Transmission fluid must be handled in clean containers fillers etc to prevent foreign material from entering the transmission Clean around the filler tube before removing the dipstick Lay the dipstick in a clean place while filling the trans
29. id or filter change intervals c Fluid Analysis Transmission protection and fluid change intervals can be optimized by monitoring fluid oxidation according to the tests and limits shown in the Table 1 4 Fonsul your telephone directory for fluid analysis firms To ensure consistent and accurate fluid analysis select only one fluid analysis firm Refer to the latest edition of GN2055EN Technician s Guide for Automatic Transmission Fluids Table 1 4 Fluid Oxidation Measurement Limits Measurement Limit Viscosity 25 change from new fluid Carbonyl absorbance 0 3 0 1 mm change from new fluid Total acid number 3 0 change from new fluid Solids 2 by volume maximum Note A Absorbance units 1 7 FLUID TEMPERATURES Ifthe sensor is located in the converter housing or input retarder valve the critical temperatures are listed in the converter out column If the sensor is located in some other area refer to the vehicle manual for the critical temperatures If the maximum fluid temperature is reached follow this procedure Stop the vehicle and shift the transmission into N Neutral and operate the engine at 1500 rpm to reduce the transmission fluid temperature If the transmission fluid does not cool in approximately 30 seconds or if it continues to overheat after operation is continued stop the vehicle and engine and locate the problem Table 1 5 Fluid Temperatures Condition C
30. into the flex disk hub 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 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 Also inspect the threaded holes for damaged threads 3 2 INSTALLING OUTPUT FLANGE AND INPUT FLANGE REMOTE MOUNTED TRANSMISSION a Output Oil Seal Check the output flange rear oil seal and input front flange oil seal for leaks or damage Replacement instructions are in the HT HTB 700 Elec tronic Control Series Service Manual SM2004EN and CL B T Series Service Man ual SM1314EN with CL B T 755 Electronic Control Series Service Manual Supplement SM1992EN Lubricate the oil seals with high temperature grease or transmission fluid b Check Yoke Inspect each flange or yoke for damage or wear The oil seal con tact surface must be smooth and regular to prevent transmission fluid leaking past the seal Rotate the flange during installation to avoid seal lip damage c Installing the Parking Brake Install the parking brake assembly on the parking brake mounting pads on the transmission and tighten the bolts to the vehicle manu facturer specifications d Installing Output Yoke Install the rear output yoke on the rear output shaft 3 3 INSTALLING PTO
31. lease Input Retarder L Adjustment for full open closed Ease of operation Driveline Proper indexing of universal and slip joints L Proper drive shaft angles Driveline backlash Lubricated universals and slip joints Hydraulic System Recommended fluid Proper fluid level in transmission Proper calibration of the dipstick Properly vented filler tube Proper filler tube and oil pan connection Clean and free of obstruction breather Transmission fluid leak Instruments and Electrical Equipment L Proper wiring and electrical connections Instruments gauges and light work correctly Shift selector display is on and DO NOT SHIFT light is off Fluid temperature gauge is working correctly Power Takeoff Proper control connection and operation Correctly coupled to driven equipment Properly connected and routed lubrication line if used 34 6 2 ROAD TEST AND VEHICLE OPERATION CHECKLIST NOTE J Refer to HT CT Transmission Operator s Handbook for operating instructions 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 Check Fluid fill the transmission with the appropriate fluid Start the Vehicle check for proper system response during start up Turn on the vehicle master ignition switch The DO NOT SH
32. light Transmission fluid pressure gauge if used Speedometer Temperature gauge if used Reverse warning system if used Transmission Fluid L Fluid level meet specifications cold neutral level No leaks Warm up and check fluid level hot neutral level No Load Governed Engine Speed No load governed speed of engine Adjust governor as necessary refer to the manufacturer s specifications for the engine transmission being tested PTO PTO operation refer to HT 700 Series Operator s Manual or to the vehicle manufacturer s specific instructions Shift Sequence L Transmission upshifts and downshifts smoothly through all ranges Other Checks Stall test Shift quality Comments 36 CUSTOMER SECTION SERVICE Vil 7 1 OWNER ASSISTANCE The satisfaction and good will of the owners of Allison transmissions are of primary concern to Allison Transmission Division ATD its distributors and their dealers As an owner of an Allison transmission you have service locations throughout the world that are eager to meet your parts and service needs with Expert service by trained personnel Emergency service 24 hours a day in many areas Complete parts support Sales teams to help determine your transmission requirements Product information and literature Normally any situation that arises in connection with the sale operation or servic
33. mission 1 5 AUTOMATIC TRANSMISSION FLUID RECOMMENDATIONS Hydraulic fluids oils used in the transmission are important influences on transmission performance reliability and durability DEXRONS III fluid is recommended for light duty applications Type C 4 fluids are recommended for severe duty applications Some DEXRON III fluids are also qualified as Type C 4 fluids To ensure the fluid is qualified for use in Allison transmissions check for a DEXRONS III or C 4 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 fluid types such as Type F and universal farm fluids may or may not be properly qualified for use in your Allison transmission CAUTION Disregarding minimum fluid temperature limits can result in transmission malfunction or reduced transmission life When choosing the optimum viscosity grade of fluid to use duty cycle preheat capabilities and or geographical location must be taken into consideration Table 1 2 lists the minimum fluid temperatures at which the transmission may be safely operated Preheat with auxiliary heating equipment or by running the vehicle with the transmission in Neutral for a minimum of 20 minutes before attempting range operation Table 1 2 Operating Temperature Requirements for Transmission Fluid Ambient Temperature Bel
34. ometer of known accuracy to the engine and install a temperature probe into the converter out to cooler line Bring the transmission to the normal operating temperature 160 200 F 71 93 CAUTION Do not attempt to stall test any transmission in reverse range Do not attempt to stall test the 755DR Series transmission in first low gear The torque produced in that gear can damage the vehicle driveline Onthe 755 Series transmissions shift the selector to D Drive range or utilize the optional stall check feature On the 741 or 748 Series shift to any forward range CAUTION Never maintain the stall condition for more than 30 seconds at any one time because of the rapid rise in transmission fluid temperature Do not let the converter out temperature exceed 300 F 149 C Do not rely on converter out temperature to limit stall duration During stall conditions internal temperatures rise much faster than converter out temperature If the stall test is repeated do not let the engine overheat With the vehicle blocked parking brake and service brake applied hold the engine at wide open throttle When the converter out temperature reaches a minimum of 255 F 124 C record the engine speed Reduce engine speed to idle and shift to N Neutral 11 c Neutral Cool Down Check Procedure The neutral cool down check determines if the transmission fluid cools following an engine load condition Perform this check
35. onverter Out Converter Operation CLBT 700 Series 275 F 135 C max HT 700 Series 300 F 149 C max Retarder Operation Intermittent 330 F 166 C max Lockup Operation 250 F 121 C max Normal Operation 180 220 F 82 105 C 1 8 HIGH EFFICIENCY MAIN PRESSURE EXTERNAL FILTER CHANGE Allison high efficiency external filters which have a change filter indicator do not need to be changed when the transmission fluid is changed unless restriction is indicated There is no mileage limitation with the use of Allison high efficiency filters An Allison high efficiency external filter element must be changed if the engine and transmission are at operating temperature over 160 F 71 C and the Change Filter light is illuminated for any length of time or the element has not been changed for three years whichever occurs first 1 9 TRANSMISSION FLUID CONTAMINATION a Examine At Fluid Change At each transmission fluid change examine the fluid that is drained for evidence of dirt or water A normal amount of condensation will emulsify in the fluid during operation of the transmission However if there is evi dence of water check the cooler heat exchanger for leakage between the water and fluid areas Fluid in the water side of the cooler heat exchanger is another sign of leakage This however may indicate leakage from the engine oil system b Metal Particles CAUTION If excessive metal contamination ha
36. ooler system Replace the transmission from cooler lube filter after 5000 miles 8000 km Refill the transmission to the correct fluid level 4 6 refer to Paragraph 1 4 CHECKING CONTROLS a Inspection Inspect the following control components and correct any faulty conditions Shift selector proper operation proper electrical connection proper harness routing Speedometer drive cable wear damage kinks lubrication proper routing Cab and chassis wiring harness proper connections frayed insulation wiring damage Throttle sensor components freedom of movement improper routing bellows damage improper or loose cable mounting Throttle sensor adjustment accuracy Parking brake controls cracks bends damaged threads clevis pins worn out rod ends 23 Hydraulic retarder control damage wear frayed cable worn out rod ends cotter pins lubrication proper operation PTO control damage wear improper operation lubrication Temperature gauge capillary tube damage if used sensor damage Fluid pressure gauge tubing damage kinks improper routing b Throttle Position Sensor TPS Adjustment When properly installed by the equipment manufacturer the TPS should not need adjustment If TPS adjustment is necessary confirm that it ha
37. output retarder or in the lubrication circuit models with an output retarder This recommendation applies whether the transmission is overhauled or replaced by a new or rebuilt unit If any doubt exists about the cleanup of the cooler replace the cooler The auxiliary filter must have at least a 40 micron filter element or finer and a maximum filter pressure drop of 2 psi 14 kPa at 15 gpm 57 liters minute at 180 F 82 C The maximum external circuit pressure drop must not exceed 30 psi 207 kPa at 15 gpm 57 liters minute at operating temperature in D Drive at full throttle stall The following auxiliary filters are recommended Table 1 6 Auxiliary Filter Recommendations Filter Assembly Filter Element Allison 29510921 Allison 29510918 AC PM 13 16 PF 897 AC PM 16 1 PF141 FX 11583 HF6520 Fram HP 1 1 HP 1 or AC HD 222 Purolator OF 15C 1 OF 2C 1 Purolator 20 10 PER 20 High efficiency filter and element are available from your authorized Allison distributor Ref SIL 12 TR 93 latest revision 1 12 BREATHER a Location and Purpose The breather is located on top of the transmission hous ing The breather prevents air pressure buildup within the transmission and its pas sage must be kept clean and open b Maintenance The amount of dust and dirt encountered will determine the fre quency of breather cleaning Use care when cleaning the transmission DO NOT SPRAY STEAM WATER OR CLEAN
38. ow Viscosity Grade Which Preheat Is Required Fahrenheit Celsius DEXRONS III 17 27 SAE 10W 4 _20 SAE 15W 40 5 15 SAE 30 32 0 SAE 40 50 10 Ref 13 TR 90 1 6 TRANSMISSION FLUID AND FILTER CHANGE INTERVALS a Frequency Transmission fluid and filter change frequency is determined by severity of transmission service and by the filter equipment installed Table 1 is a general guide More frequent changes may be required when operating conditions create high levels of contamination or overheating Table 1 3 Transmission Fluid and Filter Change Intervals Internal Sump Fluid Change Interval and Governor Standard Pressure External Filter Filter 50 000 miles 80 000 km At overhaul After first 5000 miles 8 000 km and or 12 months or 1200 at each 25 000 miles 40 000 km or hours 6 months or 600 hours thereafter Whichever occurs first An Allison high efficiency filter may be used until the change filter light indicates it is contaminated or until it has been in use for three years whichever occurs first No mileage restrictions apply b Abnormal Conditions Transmission fluid must be changed whenever there is evidence of dirt or a high temperature condition A high temperature condition is indicated by the transmission fluid being discolored or having a strong odor or by fluid analysis Local conditions severity of operation or duty cycle require more or less frequent flu
39. pter Diameter The crankshaft hub pilot or hub adapter pilot diameter must measure between 2 437 2 439 inches 61 90 61 95 mm f Crankshaft Hub Pilot or Adapter Squareness The crankshaft hub or hub adapt er cannot be out of square more than 0 005 inch 0 13 mm TIR g Crankshaft Hub Pilot or Adapter Eccentricity The crank shaft hub pilot or the hub adapter cannot be out of square more than 0 005 inch 0 13 mm TIR h Flexplate Bolt Hole Flatness Flexplate flatness in the area of the bolt holes is not a measurement required for HT and CT 700 Series flexplates i Torque Converter Axial Location Refer to Figure 4 2 Using a depth gauge measure from the torque converter housing to the torque converter s flexplate adapter mounting face The torque converter axial location should measure 3 592 3 413 inches 91 24 86 69 mm 19 4 2 CHECKING FLEXPLATE DRIVE ASSEMBLY a Flexplate Inspection Inspect the flexplate for cracks wear distortion and elon gated bolt holes Replace a damaged part b Engine Crankshaft End Play Ensure that the crankshaft end play is within the engine manufacturer s specifications c Flexplate Assembly Installation Install the flexplate onto the engine crankshaft hub using the bolts and torque values specified for that engine 4 3 CHECKING INPUT DRIVE COMPONENTS REMOTE MOUNTED TRANSMISSIONS Inspect shaft condition The shaft must not be dented or bent Welds must be sound Remove
40. s allowed 5 13 INSTALLING TEMPERATURE AND PRESSURE SENSORS CONNECTING ELECTRICAL COMPONENTS Connect the electronic control chassis harness to the transmission main connector and to the speed sensor connector Be sure the main connector is turned until a positive snap is felt Install temperature probe capillary tube and bulb or thermocouple if so equipped into the converter housing or hydraulic retarder valve If equipped with capillary tube and bulb tighten the 1 2 inch pipe thread adapter sufficiently to prevent leakage Install the bulb into the adapter and tighten the nut into the adapter Check the capillary tube for interference with other parts that might chafe or damage the tube Long tubes may require clips or brackets for support If equipped with electrical temperature sensor install thermocouple and connect electrical leads Install and connect other electrical components such as heaters winterization equipment and pressure sensors Install the pressure gauge tube or line if so equipped Ifa reverse pressure switch is mounted on the transmission at the reverse pressure port make the appropriate connection Check that all unused hydraulic openings are plugged 5 14 FILLING THE HYDRAULIC SYSTEM Select the transmission fluid Fill the transmission with the required amount of fluid refer to Section 1 9 Run the eneine for about one minute and check the tran
41. s been installed to ATD specifications The TPS is self calibrating and therefore has no optimum close throttle or full throttle count value Idle count should be 50 or higher and full throttle should be 200 or lower 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 TPS is set correctly Refer to Figure 44 c Hitch Pin Throttle Position Sensor Installation Refer to Figure 4 5 Install the throttle sensor body as follows Clamp cable end using clamp and shims Secure the sensor body using the mounting holes provided Install a heat shield if any part of the throttle sensor is near the exhaust manifold turbocharger or any other heat source Adjust the Hitch Pin throttle sensor as follows The engine fuel lever must be at the closed throttle position Install the hitch pin cable end of the sensor to the engine fuel lever with brackets so that at the idle position the cable end is 0 44 0 67 inch 11 17 mm from its fully retracted position and at wide open throttle position the cable end is 0 60 0 90 inch 15 22 9 mm from the idle position 24 255 COUNT 0 COUNT 233 COUNTS 14 COUNTS APPROX 0 75 INCH STROKE FULL THROTTLE 0 2 INCH 18 INCHES 1 9 INCHES APPROX 0 5 INCH FULLY FULLY RETRACTED EXTENDED V01942 Figure 4 4 Throttle Position Determination Diagram Check the stroke distance of the
42. s occurred replace the cooler and all bearings within the transmission Metal particles in the transmission fluid or on the magnetic drain plug except for the minute particles normally trapped in the filter indicate damage has occurred in the transmission When these particles are found in the sump the transmission must be disassembled and closely inspected to find the source Metal contamination will require complete disassembly of the transmission and cleaning of all internal and external circuits cooler and all other areas where the particles could lodge During the repair of a major internal failure of a transmission it should be dismantled into as many serviceable detail parts as possible and thoroughly cleaned Do not disassemble the unit just to the problem area c Coolant Leakage The presence of ethylene glycol coolant in the transmission fluid is detrimental to the reliability and durability of the internal components Ethylene glycol has a deteriorating effect on friction faced clutch plates and nonmetallic components seals gasket etc and on highly loaded steel parts such as bearings and gears due to reduced lubricity of the fluid d If the presence of ethylene glycol in the fluid is suspected immediately perform a verification test A Gly Tek test kit is available and is a quick and easy method to determine the presence of glycol If glycol is found disassemble and inspect the transmission and remove all traces o
43. shift to N Neutral and allow the engine to idle 500 800 rpm Insert the dipstick into the tube and remove Check the fluid level reading Repeat the check procedure to verify the reading Ifthe 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 drain as necessary to bring it to the middle of the COLD RUN band Perform a hot check as soon as the normal operating temperature of 160 200 F 71 93 C is reached c Hot Check CAUTION The transmission fluid must be hot to ensure an accurate check The fluid level rises as temperature increases Operate the transmission in D Drive until normal operating temperature is reached 160 200 F 71 93 C sump temperature 180 220 82 104 converter out temperature Parkthe vehicle on a level surface and shift to N Neutral Apply the parking brake and chock the wheels Allow the engine to idle With the engine running remove the dipstick from the tube and wipe it clean Insert the dipstick into the tube and remove Check fluid level reading Repeat the check procedure to verify the reading NOTE Safe operating level is within the RUN band on the dipstick Figure 1 1 Ifthe fluid level is not within the HOT RUN band add or drain as necessary to bring the fluid level to within t
44. smission fluid level refer to Section 1 3 32 CHECKS AND SECTION ADJUSTMENTS VI 6 1 INSTALLATION CHECKLIST Use this list after transmission installation As items are checked mark them off this list Torque Values Flexplate bolts 96 115 Ib ft 131 155 N m Transmission to engine bolts Transmission to frame or mounting bolts Input flange nut 450 550 Ib ft 611 745 N m Output flange nut 600 800 Ib ft 814 1084 N m Companion flange or universal joint bolts Speedometer cable nut 52 Ib in 6 N m Speedometer body 45 50 Ib ft 62 67 N m Hydraulic lines to transmission 40 50 Ib ft 55 67 N m max Cooler lines to and from retarder 50 59 Ib ft 68 79 N m Drain plug 15 20 Ib ft 20 27 N m Speed sensor bolt 20 23 Ib ft 28 31 N m PTO mounting bolts if PTO used Reverse signal switch to transmission if so equipped 48 60 Ib in 5 5 6 7 N m Parking brake bolts to transmission 117 140 Ib ft 159 189 N m Center bolt external filter 75 Ib in 8 5 N m Cooler Fluid Lines and Air Hose No Leaks Connection Tightness Correct Routing Tighten to vehicle manufacturer s recommendation 33 Throttle Position Sensor Proper Adjustment Correct routing of cable and harness Parking Brake Proper clearance Adjustment for full application C Check for full re
45. smission product is greatly appreciated and it is our sincere desire to assure complete satisfaction 38 7 2 SERVICE LITERATURE Additional service literature is available This service literature provides fully illustrated instructions for the operation maintenance service overhaul and parts support of your transmission To ensure that you get maximum performance and service life from your unit see your dealer or distributor for the following publications Check the telephone directory for the Allison Transmission service outlet nearest you Table 7 1 Service Literature Publication HTB 700 Series CLT CLBT 700 Series Service Manual SM2004EN SM1314EN SM1992EN SM1992EN Parts Catalog PC1965EN PC1993EN Troubleshooting Manual TS2712EN TS2712EN Operator s Manual OM1957EN OM1957EN Technician s Guide GN2009EN GN2055EN GN2033EN GN2033EN GN2055EN Electronic Control Service Manual Supplement Automatic Transmission Fluid HT CLBT Series Inspection Analysis HTB Series Hydraulic Output Retarder Inspection Analysis 39 PC1958EN 199503 Printed in U S A 199904
46. the dirt or any foreign matter to enter the transmission Dirt or foreign matter may cause undue wear of the transmission parts make valves stick and clog passages Check the fluid level manually using the following procedure and record the level in your maintenance log To perform the fluid level check the engine must be running at idle speed and the transmission must be in N Neutral Add transmission fluid to the transmission through the fill tube opening Be sure to use proper transmission fluid and fluid containers as discussed ir Sections 1 4 ind 1 5 R efer to Table 1 1 for approximate transmission fluid capacity Table 1 1 Transmission Fluid Capacity Application U S Quarts Liters 414 inch 114 mm oil pan 34 32 6 inch 152 mm oil pan 30 28 5 7 inch 178 mm oil pan 30 28 5 81 2 inch 215 mm oil pan 43 41 NOTE Does not include external circuits b Cold Check NOTE J 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 Park the vehicle on a level surface Apply the parking brake and chock the wheels CAUTION The fiuid level rises as fluid temperature increases DO NOT fill above the COLD RUN band if the transmission fluid is below normal operating temperatures Run the engine for at least one minute Shift to D Drive and then to R Reverse to clear the hydraulic circuits of air Then
47. throttle sensor from closed to wide open Stroke distance must be from 0 60 0 90 inch 15 22 9 mm Recheck for zero clearance at the fuel lever Make sure that the 0 60 0 90 inch 15 22 9 mm dimension has not changed Design throttle sensor linkage brackets and levers to nominal dimensions so that the system stays within tolerance band throughout its operating life Slip Link Throttle Sensor Installation Refer to Figure 4 6 Loosen 14 20 nuts and B enough to let the threaded shaft move to its fully retracted position Make sure the engine fuel lever is at the closed throttle position Tighten nut A against the slip link until the threaded shaft moves 0 44 0 66 inch 11 2 16 7 mm from its retracted position Check to be sure there is zero clearance between the drive pin on the fuel lever and the end of the slot in the slip link Then tighten nut B securely against the slip link Recheck for zero clearance at the fuel lever Then recheck the 0 44 0 66 inch 11 2 16 7 mm dimension to ensure that it has not changed Move the throttle from closed to wide open to check the stroke distance of the throttle sensor The stroke distance must be within the range of 0 63 0 86 inch 16 0 21 8 mm 25 Fuel lever attachment linkage or bracket must allow fuel lever to return to closed throttle position even when sensor rod is maintained at full throttle position Attach to engine or governor housing using clamp
48. ut retarder control linkage if input retarder is used A SPEED SENSOR SPEEDOMETER DRIVE OPENING BULKHEAD CONNECTOR L01498 01 Figure 2 1 Disconnect Locations 2 3 UNCOUPLING FROM DRIVELINE ENGINE AND VEHICLE Disconnect the vehicle driveline from the transmission output flange Position the disconnected shaft to avoid interference when removing the transmission If transmission mounts support the rear of the engine place a jack or other support under the engine Support the transmission securely on a hoist jack or other suitable removal equipment Remove all bolts nuts washers spacers and supports that attach the transmission to the vehicle and to the engine reference Figure 4 1 2 4 REMOVING THE TRANSMISSION Move the transmission away from the engine 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 2 5 REMOVING INPUT AND OUTPUT FLANGES OR YOKES When replacing the transmission it may be necessary to transfer input and output flanges or yokes to the replacement transmission If the flanges or yokes are retained by a large self locking nut follow specific procedures below for removal of the nut CAUTION The use of an impact wrench for removing the input or output nut requires a means to hold the flange Failure to hold the flange can cause internal
49. 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 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 COOLER FILTER AND LINES a Inspection Perform the following and correct any faulty conditions Transmission fluid cooler and related coolant lines Check for contamination clean and flush as necessary Inspect for deterioration Inspect for faulty connectors or kinks Clean and flush transmission fluid cooler both coolant and oil sides Pressure check both sides using a 40 psi 276 kPa air supply 22 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 over haul cannot be assumed Repeated cleaning and flushing may not remove all debris from the transmission fluid c
Download Pdf Manuals
Related Search