PRODUCT FAMILIES - Allison Transmissions
Contents
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5. Screwdriver slot to aid removal V05824 Figure 6 1 Pilot Tool for Transmission To Engine Alignment 7 Push the transmission toward the engine while guiding the pilot boss on the torque converter into the flexplate hub adapter or flywheel and the guide bolt into the hole on the flexplate a headless guide bolt in the engine flywheel housing may also aid in the transmission installation 8 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 9 Align the bolts holes in the converter housing with those in the engine flywheel housing 57 10 Install all transmission to engine bolts and washers finger tight a minimum of 10 bolts is required and must include the top two flush against the engine flywheel housing before tightening any bolts DO NOT use the bolts to seat the housing CAUTION The entire converter housing circumference must be 11 Tighten four bolts at equally spaced intervals around the converter housing bolt circle Use the torque specified by the engine or vehicle manufacturer 12 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 b
6. SECTION TRANSMISSION PREPARATION 4 1 CHECKING INPUT COMPONENTS 4 2 INSTALLING OUTPUT FLANGE YOKE 423 sINSTALLING PTO ak Gok Pe ET et ast 4 4 INSTALLING FILL TUBE AND aaa 4 5 CHECKING PLUGS AND OPENINGS SECTION V PREPARING VEHICLE FOR TRANSMISSION INSTALLATION 5 1 ENGINE TRANSMISSION ADAPTATION REQUIREMENTS 5 2 5 3 5 4 5 5 CHECKING FLEXPLATE DRIVE ASSEMBLY 50 CHASSIS AND DRIVELINE 50 COOLER FILTER 5 51 CHECKING CONTROLS 52 SECTION INSTALLING TRANSMISSION INTO VEHICLE 6 1 HANDLING 4er cie 565 x ede RW sus 56 6 2 MOUNTING TO ENGINE 56 6 3 INSTALLING TRANSMISSION MOUNTING COMPONENTS 58 6 4 COUPLING 58 6 5 CONNECTING POWER TAKE OFF CONTROLS 59 6 6 CONNECTING PARKING 59 6 7 CONNECTING COOLER wg ala BES 59 6 8 CONNECTING CONTROLS 60 6 9 FILLING HYDRAULIC SYSTEM 61 6 10 INSTALLATION CHECKLIST 61 6 11 ROAD TEST AND VEHICLE OPERATION CHECKLIS
7. Inspect for deterioration Inspect for faulty connectors or kinks Clean and flush transmission fluid cooler both coolant and oil sides using J 46550 A Transmission Cooler Kwik Cart Pressure check both sides using a 276 kPa 40 psi air supply Hydraulic lines 51 Check for contamination clean and flush as necessary nspect 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 Refer to GN4008EN In Chassis Maintenance for cooler flushing procedure NOTE When equipment to flush the oil cooler is not available install a filter in the cooler line between the oil cooler and the transmission from cooler port The cooler circuit pressure drop specifications must still be met For 1000 Product Family transmissions pressure drop must not exceed 241 kPa 22 7 liters min flow 35 psi 6 0 gal min For 2000 Product Family transmissions pressure drop must not exceed 159 kPa 30 3 liters min flow 23 psi 8 0 gal min Frequent initial changes of this filter element may be required as debris is flushed out of the oil cooler circuit Closely monitoring change in cooler circuit pressure drop will indicate when a filter change is needed 5 5 CHECKING CONTROLS a Inspection Inspect the following and cor
8. MECHANIC S TIPS 1000 2000 PRODUCT FAMILIES ALLISON 4th GENERATION CONTROLS 2008 DECEMBER MT4007EN Allison Transmission Allison 4 Generation Controls 1000 and 2000 Product Families 2 Allison Transmission Allison Transmissi ion Inc P O Box 894 m dust Indiana 46206 0894 www allis Printed in USA Copyright 2009 Allison Transmission Inc NOTES TABLE OF CONTENTS SECTION INTRODUCTION 1 1 SECTION PREVENTIVE MAINTENANCE 2 1 PERIODIC INSPECTION AND CARE 2 2 PROGNOSTICS 2 2 ak OA et tee 2 3 IMPORTANCE OF PROPER TRANSMISSION FLUIDLEVEL 2 4 TRANSMISSION FLUID 2 5 KEEPING FLUID CLEAN 2 6 FLUID RECOMMENDATIONS 27 TRANSMISSION FLUID AND FILTER CHANGE INTERVALS 2 8 TRANSMISSION FLUID CONTAMINATION 2 9 TRANSMISSION FLUID AND FILTER CHANGE PROCEDURE 2 10 BREATHER inse cuim c 5 uersu 6 RU gd Boe SECTION REMOVING TRANSMISSION 3 1 DRAINING TRANSMISSION 3 2 DISCONNECTING CONTROLS 3 3 UNCOUPLING FROM DRIVELINE ENGINE ANDVEHICLE 3 4 REMOVING THE TRANSMISSION 3 5 REMOVING THE FLEXPLATE ADAPTER 3 6 REMOVING OUTPUT FLANGE OR YOKE
9. 32 c Refill Transmission Refer to Table 2 6 for fluid refill quantities The amount of refill fluid is less than the amount used for the initial fill Fluid remains in the external circuits and transmission cavities after draining the transmission After refill check the fluid level using the procedure described in 2 4 TRANSMISSION FLUID CHECK NOTE Quantities listed are approximations and do not include external lines and cooler hose Table 2 6 Transmission Fluid Capacity aa ee 2 10 BREATHER a Location and Purpose The breather is located on top of 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 CAUTION When cleaning the transmission do not spray steam water or cleaning solution directly at the electrical connectors Spraying steam water or cleaning solution at the electrical connectors can cause codes and cross talk CAUTION When cleaning the transmission do not spray steam water or cleaning 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 NOTE Fluid loss out of the breather in cold
10. TRANSMISSION THROUGH PTO TRANSMISSION MAIN PRESSURE MANUAL HYDRAULIC EE E VALVE OR SOLENOID VALV FROM COOLER PORT PTO LUBE LINE with 0 81 mm 0 032 in orifice V05817 Figure 4 3 PTO Clutch Pressure Plumbing Schematic e Connect PTO Clutch Feed if required Some PTOs are clutch applied Use transmission main pressure from the main pressure tap for applying the PTO clutch Refer to Figure 4 1 for the location of the main pressure tap and Figure 4 3 for a typical plumbing schematic when this feature is needed This connection can be made later if the clutch apply line will interfere with transmission installation 4 4 INSTALLING FILL TUBE AND SEAL a Location The fill tube may be mounted on either the right or left side The unused fill tube provision must have a plug to fill the tube opening 42 self tapping screw which is 24 0 mm 0 95 inch A screw that is too long may cause cracks and leaks in the main housing Refer to AS64 065 in the Allison Sales Tech Data Book on the Allison Extranet for the correct screw specifications CAUTION Install the fill tube bracket with the correct length M8 b Installation If the fill tube will interfere with the installation of the transmission delay this step until after the transmission is in the vehicle Install the fill tube seal into the main housing Insert the fill tube through the seal until the shoulder at the bottom of the
11. or PB Auto Apply Parking Brake if available or N Neutral for a minimum of 20 minutes before attempting range operation Table 2 1 Transmission Fluid Operating Temperature Requirements Ambient Temperature Below Which Preheat is Required TranSynd or TES 295 DEXRON VI or 25 13 TES 389 Ref SIL 10 TR 99 NOTE Transmission ranges available and torque converter clutch operations are limited when the transmission fluid temperature is below 25 C 13 F 26 2 7 TRANSMISSION FLUID AND FILTER CHANGE INTERVALS CAUTION Transmission fluid and filter change frequency is determined by the severity of transmission service More frequent changes may be necessary than recommended in the general guidelines when operating conditions create high levels of contamination or overheating a Frequency New vehicles delivered from the OEM with a mixture of Allison approved TES 295 fluid and non approved fluid or TES 389 Allison approved fluid must follow fluid filter change recommendations outlined in Table 2 2 If the customer fills the transmission with Allison approved TES 295 fluid or TES 295 equivalent the change recommendations of Table 2 2 must be followed Upon the next oil change if the customer reinstalls Allison approved TES 295 fluid the fluid filter change recommendations outlined in Table 2 3 may be used The recommendations in Table 2 3 are based upon Allison fluid change procedures a
12. the seal to leak b Check Flange or Yoke Check each flange or yoke for damage or wear The oil seal contact surface must be smooth and regular to prevent oil leaking past the seal Rotate the flange after installation to check for binding 37 c Install Output Flange or Yoke CAUTION Be sure that the flange output shaft and retaining hardware are clean Care must be exercised to avoid transmission output seal or journal damage Check to verify that the seal is free of tears and cuts Nicks and scratches must not exist on the lead in chamfer or seal journal section of the output flange or yoke 1 Lubricate the splines of the output shaft and the oil seal assembly with transmission fluid or oil soluble grease flange yoke onto the shaft Forcing the flange yoke onto the shaft CAUTION Do not use a hammer or other similar tool to force the may result in transmission damage 2 Start the yoke flange assembly onto the output shaft ensuring that the splines are properly engaged and slide freely Push the yoke flange assembly into the rear cover module 3 Install a new output shaft sealing washer and the output shaft bolt CAUTION Use of an impact wrench requires the retention of the yoke flange to prevent internal transmission damage 4 Tighten the output shaft bolt to 108 136 N m 80 100 Ib ft 5 Rotate the yoke flange assembly by hand to check for binding interference and ru
13. Cross Section with Park Pawl 10 00 0 Z6990A 02 0 1 7 6 N NOILY907 3801 7115 Old 1108 9 375 5 HOl10313S YOSN3S 03345 LAdLNO q33dS NOISIAOHd HOSN3S 43395 SNIGYNL Figure 1 4 1000 and 2000 Product Families Left Front View 11 SENSOR ENGINE SPEED SAE 3 HOUSING ONLY COOLER PORTS MOUNTING PAD AVAILABLE OIL FILL TUBE LOCATION NAMEPLATE MAIN ELECTRICAL CONNECTOR ax az Ow JIZ m zu cc EOS oc Ot LE orga lt ac o lt tn Ow gt a LE 2 o V06693 00 03 Figure 1 5 1000 and 2000 Product Families Right Rear View 12 PREVENTIVE MAINTENANCE 2 1 PERIODIC INSPECTION AND CARE a Transmission Inspection CAUTION When cleaning the transmission do not spray steam water or cleaning solution directly at the electrical connectors Spraying steam water or cleaning solution at the electrical connectors can cause codes and cross talk CAUTION When cleaning the transmission do not spray steam water or cleaning 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 Clean and i
14. ambient conditions during engine start may be remedied by venting the fill tube refer to SIL 6 1k2k 06 33 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 2 8 TRANSMISSION FLUID CONTAMINATION 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 3 2 DISCONNECTING CONTROLS 1 Disconnect the external wiring harness at the feedthrough harness connector Loosen the bolt that retains the 24 way feedthrough connector to the transmission Refer to Figure 1 4 or Figure 1 5 Prevent dirt or moisture from entering a disconnected connector Position the wiring harness so it does not interfere with transmission removal 2 Disconnect linkage from the customer furnished transmission shift lever Position the disconnected linkage so it does not interfere with transmission removal Leave the
15. and torque values specified for that engine Refer to Figure 5 1 Figure 5 2 or Figure 5 3 for the proper position of an installed flexplate 5 3 CHASSIS AND DRIVELINE INSPECTION Inspect the chassis and driveline components for the following conditions and correct them as appropriate Transmission mounts broken or worn out Bolts and other hardware damaged missing or incorrect solators rubber mounts damaged or missing 50 Driveline angles runout or balance which does not conform to the manufacturer s recommendations Driveline yoke slip joints freedom of movement damaged or worn out correctly lubricated correctly indexed 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 e 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 Check for contamination clean and flush as necessary
16. fill tube contacts the seal Align the tube bracket with its bolt location Install the fill tube bolt and tighten until it is firmly seated against the bracket 43 FROM COOLER PORT PTO LUBE LINE with 0 81 mm 0 032 in orifice COOLER RETURN OIL LINE ENLARGED DETAIL 05816 Figure 4 4 4 5 CHECKING PLUGS AND OPENINGS Carefully check all sides and the bottom of the transmission for loose or missing plugs a Pressure Plugs Check that 4375 20 UNF 2A pressure plugs are tightened to 10 13 N m 7 10 Ib ft b Fluid Drain Plug Check that the drain plug is tightened to 30 40 N m 22 30 Ib ft c Tachograph Plug If present tighten to 60 67 N m 44 49 Ib ft 44 d 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 Service Information Letter 17 TR 94 45 PREPARING Ee VEHICLE FOR JO TRANSMISSION Section V INSTALLATION 5 1 ENGINE TRANSMISSION ADAPTATION REQUIREMENTS You must make sure a new transmission installation can be adapted to the vehicle s engine Use the measurements described in this section to make sure correct transmission to engine adaptation Refer to Figure 5 1 or Figure 5 2 and or 567 020 Typical arrangement of adaptation components
17. 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 30 d Metal Metal particles in the fluid except for the minute particles normally trapped in the oil filter indicate internal transmission damage If these particles are found in the sump the transmission must be disassembled and closely inspected to find their source Metal contamination requires complete transmission disassembly Clean all internal and external hydraulic circuits cooler and all other areas where the particles could lodge CAUTION After flushing the cooler 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 NOTE When equipment to flush the oil cooler is not available install a filter in the cooler line between the oil cooler and the transmission from cooler port The cooler circuit pressure drop specifications must still be met see AS64 071 or AS64 072 in the Allison Sales Tech Data book SA3018EN Frequent initial changes of this filter element may be required as debris is flushed out of the oil cooler circuit Closely monitoring change in cooler circuit pressure drop will indicate when a filter change is needed 2 9 TRANSMISSION FLUID AND FILTER CHANGE PR
18. shift lever on the transmission 3 If PTO s is are used disconnect the PTO s wiring harness es 4 If parking brake is present disconnect linkage 34 3 3 UNCOUPLING FROM DRIVELINE ENGINE AND VEHICLE WARNING Chock wheels to prevent vehicle from moving when driveline is disconnected This is not necessary if vehicle is on a lift or jackstands 1 Disconnect the vehicle drive shaft from the transmission output flange or yoke Position the disconnected shaft to avoid interference when removing the transmission 2 If PTO equipped disconnect PTO connections such as a PTO hydraulic hoses b PTO powered equipment drive shaft 3 If transmission mountings support the rear of the engine place a jack or other support under the engine 4 Securely support the transmission with a hoist jack or other suitable removal equipment NOTE It may be necessary to remove an engine flywheel housing access cover to remove flexplate or flexplate adapter bolts This is the engine to transmission connection 5 Remove all bolts nuts washers spacers and supports that attach the transmission to the vehicle and the engine 3 4 REMOVING THE TRANSMISSION CAUTION Do not pull the transmission away from the torque converter assembly The torque converter drive cover must be entirely free of any restraint by the flexplate drive or crankshaft pilot when the transmission separates from the engine WARNING Be sure
19. tables are given only as a general guide for fluid and filter change intervals Table 2 2 Schedule 1 Recommended Fluid and Filter Change Intervals Allison Approved Non TES 295 Fluids Control Vocation Main Lube Auxiliary 50 000 miles 50 000 miles 50 000 miles 80 000 km 80 000 km Overhaul 80 000 km 24 months 24 months 24 months 2000 hours 2000 hours 2000 hours 12 000 miles 12 000 miles 12 000 miles 20 000 km 20 000 km 20 000 km Severe 6 months 6 months Overhaul 6 months 500 hours 500 hours 500 hours Allison approved non TES 295 fluid is defined as the quantity of oil remaining in the transmission after a standard fluid change combined with the quantity of Allison approved TES 295 fluid that is required to fill the transmission to the proper level A mixture of Allison approved TES 295 fluid vs non TES 295 fluids other than as defined in this paragraph does not meet the requirements that permit the eligibility for the recommendations given in Schedule 2 Control Main Spin on Filters Only lnitial 10 000 miles 16 000 km or first engine oil change whichever comes first 28 Table 2 3 Schedule 2 Recommended Fluid and Filter Change Intervals 100 Percent Concentration of Allison Approved TES 295 Fluids 150 000 miles 50 000 miles 50 000 miles 240 000 km 80 000 km Overhaul 80 000 km 48 months 24 months 24 months 4000 hours 2000 hours 2000 hours 75 000 miles 50 000 miles 50 000 mile
20. the torque converter is moving rearward with the transmission as it is removed Do not allow the torque converter to become disengaged from the oil pump or to fall completely out of the transmission causing damage and or personal injury 1 Move the transmission away from the engine approximately 34 6 mm 1 36 inch for a number 2 flywheel housing or 44 2 mm 1 74 inch for a number 3 flywheel housing until it is completely clear of the engine If used remove the adapter ring and or gasket 35 2 Raise or lower the transmission as necessary to remove it from the vehicle 3 5 REMOVING THE FLEXPLATE ADAPTER 1 Remove the flexplate adapter if present from the front of the torque converter This part will be needed for transfer if a replacement transmission is being installed WARNING Handle the transmission carefully whenever the torque converter retaining bracket is not present NEVER tilt the converter end down or the torque converter can slide forward disengaging the oil pump or can fall completely out of the transmission causing damage and or personal injury 2 Attach a torque converter retaining bracket at the earliest opportunity The bracket keeps the torque converter from sliding out of engagement with the oil pump or from falling off completely and being damaged or causing personal injury 3 6 REMOVING OUTPUT FLANGE OR YOKE If replacing the transmission you may need to transfer the output flange o
21. the transmission in a manner that assures satisfactory operation and long service life For additional detailed information refer to the Service Manual SM4006EN and Troubleshooting Manual TS3977EN Unless specifically indicated otherwise this handbook refers to all Allison 4 Generation Controls 1000 and 2000 Product Families transmissions The differences between the various transmissions are explained as required l13VHS 1 HOLNTD H LNT 20 Old HO T33HM 3NOI HAMA NOLINS JINGOW 12 JINGOW IMYA TOHLNOD NVd AYVLANV1d 1 AYVLANV1d TMVd 00 00 67 60 AYVLANV1d d 5 LAdLNO YOSNAS 03345 LNdLNO 43409 uvau FINGOW 43409 3304 LAdLNO 14VHS HOSN3S 5 H LNT 90 13395 HOLNID 1 7 1909915 LNOH4 HOLNTD 20 ONISNOH NIYIN HOSN3S 03395 LNdNI JINON ONISNOH NIVIN H3183ANO2 FINGOW LYOddNS LNOYS ONISNOH H31H3ANOO 0 A18NN3SSV H3183ANOOD 1 Figure 1 1 1000 and 2000 Product Families Cross Section With Park Paw
22. ATIONS CAUTION DEXRONS VI is restricted to 1000 2000 transmissions beginning with serial number 6310670488 Hydraulic fluids oils used in the transmission are important influences on transmission performance reliability and durability Only fluids meeting TES 295 TES 389 DEXRONC III or DEXRON VI fluid specifications are acceptable for use in 1000 and 2000 Product Families transmissions TranSynd is a full synthetic transmission fluid developed by Allison 25 Transmission and Castrol Ltd and is fully qualified to the GM DEXRON VI specifications NOTE Allison Prognostics must only be used with Allison approved TES 295 fluids To make sure the fluid is qualified for use in Allison transmissions check for a TES 389 or TES 295 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 CAUTION Disregarding minimum fluid temperature limits can result in transmission malfunction or reduced transmission life When choosing the optimum viscosity grade of fluid duty cycle preheat capabilities and or geographical location must be taken into consideration Table 2 1 lists the minimum fluid temperatures at which the transmission may be safely operated without preheating the fluid Preheat with auxiliary heating equipment or by running the equipment or vehicle with the transmission in P Park
23. EN for a current listing of Allison Transmission authorized distributors and service dealers 7 2 SERVICE LITERATURE Refer to Table 7 1 for available service literature This service literature provides fully illustrated instructions for operation maintenance service overhaul and parts support for your transmission To be sure that you get maximum performance and service life from your unit 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 Table 7 1 Available Service Literature Mechanic s Tips Bus Series Operator s Manual Highway Series Operator s Manual OM3757EN Motorhome Series Owner s Manual OM3364EN Emergency Vehicle Series Operator s Manual OM3761EN 66 Table 7 1 Available Service Literature cont d Also available on the internet at www allisontransmission com 67 NOTES 68 TECHNICAL PUB Information highway Visit www allisontransmission com for a comprehensive library of informational publications including Mechanic s Tips Parts Catalogs Troubleshooting Manuals and Service Manuals DRIVING TRANSMISSION TECHNOLOGY Allison MT4007EN 200901 Printed in USA 200901 Transmission
24. OCEDURE a Drain Fluid 1 Drain the fluid when the transmission is at normal operating sump temperature 71 C to 93 C 160 F to 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 2 8 TRANSMISSION FLUID CONTAMINATION b Replace Control Main Filter Refer to Figure 2 3 during the following procedure 1 Remove the control main filter by rotating it in the counterclockwise direction Use a standard strap type filter wrench 2 Remove the magnet from the filter attachment tube or from the top of the filter element 3 Clean any metal debris from the magnet Report any metal pieces larger than dust to your service management 4 Reinstall the magnet onto the filter attachment tube 31 5 Lubricate the gasket on the control main filter with transmission fluid 6 Install by hand the control main filter until the gasket on the control main filter touches the converter housing or cooler manifold CAUTION Turning the control main filter more than ONE FULL TURN after gasket contact will damage the filter 7 Turn the filter ONE FULL TURN ONLY after gasket contact 8 Reinstall the drain plug and sealing washer Tighten the drain plug to 30 40 N m 22 30 Ib ft RD e QN 05805 Figure 2 3 Replacing Control Main Filter
25. T 63 SECTION CUSTOMER SERVICE 7 1 7 2 OWNER ASSISTANCE 66 SERVICE LITERATURE on Beet ot ide beaten ea dalek gud 66 TRADEMARK USAGE The following trademarks are the property of the companies indicated Allison DOC is a trademark of General Motors Corporation e DEXRON is a registered trademark of General Motors Corporation TranSynd is a trademark of Castrol Ltd WARNINGS CAUTIONS NOTES YOUR RESPONSIBILITY to be completely familiar with the warnings and cautions in this handbook It is however important to understand that these warnings and cautions are not exhaustive Allison Transmission could not possibly know evaluate and advise the service trade of all conceivable ways in which service might be done or of the possible hazardous consequences of each way The vehicle manufacturer is responsible for providing information related to the operation of vehicle systems including appropriate warnings cautions and notes Consequently Allison Transmission has not undertaken any such broad evaluation Accordingly ANYONE WHO USES A SERVICE PROCEDURE OR TOOL WHICH IS NOT RECOMMENDED BY ALLISON TRANSMISSION OR 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
26. able end is 11 17 mm 0 44 0 67 inch from its fully retracted position and at wide open throttle the cable end is pulled an additional 15 22 9 mm 0 60 0 90 inch from the idle position Recheck the stroke distance of the throttle sensor from closed to wide open after installation is completed Check the stroke distance of the throttle sensor from closed to wide open Stroke distance must be from 15 22 9 mm 0 60 0 90 inch Recheck for zero clearance at the fuel lever Make sure that the 15 2 22 9 mm 0 60 0 90 inch dimension has not changed Design throttle sensor linkage brackets and levers to nominal dimensions so that the system stays within tolerance bands throughout its operating life 55 INSTALLING TRANSMISSION Section VI 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 TO ENGINE WARNING The torque converter must be held to the torque 1 converter housing by retaining device such as shipping brackets Without the retaining device the torque converter may slide forward disengaging the oil pump or may fall completely out of the transmission causing personal injury and or property damage WARNING The 1000 and 2000 Product Famil
27. at the engine is at low idle rpm Put the transmission in P Park N Engage the Park range by slowly releasing the service brake 5 Apply the emergency brake and or parking brake if present and make sure it is properly engaged 6 If the operator s station will be unoccupied with the engine running chock the wheels and take any other steps necessary to keep the vehicle from moving If this procedure is not followed the vehicle can move suddenly and you or others could be injured WARNING For vehicles containing 2000 Product Family transmissions with auto apply parking brakes each time you park the vehicle or leave the operator s station with the engine running do the following 1 2 3 Bring the vehicle to a complete stop using the service brake Make sure that the engine is at low idle rpm Put the transmission in PB Auto Apply Parking Brake and make sure that the parking brake is properly engaged Engage the P Park range by slowly releasing the service brake Apply the emergency brake if present and make sure it is properly engaged If the operator s station will be unoccupied with the engine running chock the wheels and take any other steps necessary to keep the vehicle from moving If this procedure is not followed the vehicle can move suddenly and you or others could be injured WARNING For vehicles containing 2000 Product Family trans
28. bolts 10 13 N m 7 10 Ib ft 0 250 20 bolts 12 15 N m 9 11 Ib ft Cooler Fluid Lines and Air Hose for No leaks Connection tightness Correct routing Throttle Sensor for Proper adjustment Correct routing of cable and harness Driveline for Proper indexing of universal joints Proper drive shaft angles Driveline backlash Lubricated universals and slip joints Hydraulic System for Recommended fluid refer to 2 6 FLUID RECOMMENDATIONS and 2 7 TRANSMISSION FLUID AND FILTER CHANGE INTERVALS Correct fluid level in transmission Dipstick correctly calibrated Figure 2 1 and Figure 2 2 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 62 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 Clutch apply line correctly installed and routed if used 6 11 ROAD TEST AND VEHICLE OPERATION CHECKLIST a Driveability NOTE Refer to the latest edition of the applicable Operator s Manual refer to 7 2 SERVICE LITERATURE Drive away checks are performed to verify proper transmission and suppor
29. c4 3VS SNISNOH 80 AVS Figure 5 3 Typical Arrangement of Adaptation Components 49 g Crankshaft Hub Pilot or Adapter Concentricity The crankshaft hub pilot or the hub adapter pilot concentricity cannot exceed 0 25 mm 0 010 inch TIR h Flexplate Bolt Hole Flatness Flexplate flatness must be 0 76 mm 0 030 inch TIR or less when measured at 292 mm 11 5 inch diameter i Torque Converter Axial Location This is controlled by the engine physical adaptation Using a depth gauge measure from the face of the engine flywheel housing to the face at the 292 1 mm 11 50 inches diameter The torque converter axial location should measure No 3 Housing 40 15 44 21 mm 1 581 1 741 inches No 2 Housing 30 50 34 56 mm 1 201 1 361 inches 5 2 CHECKING FLEXPLATE DRIVE ASSEMBLY a Flexplate Inspection Check the flexplate for cracks distortion or elongated bolt holes Replace a worn or damaged flexplate b Engine Crankshaft End Play Make sure engine crankshaft end play is within the engine manufacturer s specifications NOTE When assembling the flexplate to the crankshaft hub or hub adapter make sure the outer flexplate bolt holes are aligned NOTE When assembling the flexplate to the crankshaft hub or hub adapter make sure the outer flexplate bolt holes are aligned c Flexplate Assembly Installation Install the flexplate onto the engine crankshaft hub using the bolts
30. dILSdid 1 Tilda SNOT Figure 2 2 Long Fill Tube and Dipstick Requirements 21 a Manual Fluid Check Procedure Clean all dirt from around the top of the fluid fill tube before removing the dipstick Do not allow dirt or foreign matter to enter the transmission Dirt or foreign matter in the hydraulic system may cause undue wear of transmission parts make valves stick and clog passages Check the fluid level using the following procedure and report any abnormal fluid levels to your service management b Cold Check Procedure The purpose of the cold check is to determine if the transmission has enough fluid to be operated safely until a hot check can be made NOT fill above the COLD CHECK band if the transmission fluid is below normal operating temperatures CAUTION The fluid level rises as fluid temperature increases DO 1 Park vehicle as follows a For vehicles containing 1000 and 2000 Product Families transmissions with park pawl 1 Bring the vehicle to a complete stop on a level surface using the service brake 2 Make sure that the engine is at low idle rpm 3 Put the transmission in P Park 4 If a parking brake is present apply the parking brake Make sure that the parking brake is properly engaged 5 Engage the P Park range by slowly releasing the service brake 6 Apply the emergency brake if present and make sure it is properly engaged 7 Chock the whee
31. ed 2 Fill the transmission with the required amount of Allison approved fluid refer to 2 9 TRANSMISSION FLUID AND FILTER CHANGE PROCEDURE 2 6 FLUID RECOMMENDATIONS 3 Run the engine for about one minute and check the fluid level refer to 2 4 TRANSMISSION FLUID CHECK 6 10 INSTALLATION CHECKLIST Use this list after transmission installation As items are checked mark them off this list Torque Values All oil pan bolts 24 29 N m 18 21 Ib ft Main pressure tap 10 13 N m 7 10 Ib ft Cooler fittings 0 750 16 inch series 30 36 N m 22 27 Ib ft 1 0625 12 inch series 56 69 N m 41 51 Ib ft Cooler manifold bolts 24 29 N m 18 21 Ib ft Flexplate adapter to converter cover bolts 57 68 N m 42 50 Ib ft Flexplate to crankshaft hub bolts consult engine manufacturer specifications Flexplate to flexplate adapter bolts 57 68 N m 42 50 Ib ft Fluid drain plug 30 40 N m 22 30 Ib ft Fluid fill tube bracket bolt firmly seated against bracket 61 Speed sensor bolts 10 13 N m 7 10 Ib ft Output flange bolt 108 136 N m 80 100 Ib ft PTO cover bolts 40 45 N m 29 33 Ib ft PTO mounting bolts 857 68 N m 42 50 Ib ft Selector lever nut customer supplied 20 27 N m 15 20 Ib ft PTO pressure hose fitting to transmission 10 13 N m 7 10 Ib ft Rear cover bolts 51 61 N m 38 45 Ib ft TPS to engine bracket M6
32. equipment The service procedures recommended by Allison Transmission or the vehicle manufacturer and described in this handbook are effective methods for performing service operations Some of these service operations require the use of tools specially designed for the purpose The special tools should be used when and as recommended Three types of headings are used in this manual to attract your attention These warnings and cautions advise of specific methods or actions that can result in personal injury damage to the equipment or cause the equipment to become unsafe WARNING A warning is used when an operating procedure practice etc if not correctly followed could result in personal injury or loss of life CAUTION A caution is used when an operating procedure practice etc if not strictly observed could result in damage to or destruction of equipment 65 NOTE A note is used when an operating procedure practice etc is essential to highlight INTRODUCTION 1 1 INTRODUCTION This manual is a mechanic s reference for maintaining removing or installing Allison 4 Generation Controls 1000 and 2000 Product Families transmission in a manner that assures satisfactory operation and long service life All features of the transmission and the vehicle involved in installation procedures are discussed The information presented will help the mechanic maintain remove or install
33. g remove the dipstick from the tube and wipe the dipstick clean Insert the dipstick into the tube and remove Check the fluid level reading Repeat the check procedure to verify the reading If the fluid level is within the COLD CHECK band the transmission may be operated until the fluid is hot enough to perform a HOT RUN check If the fluid level is not within the COLD CHECK band add or drain as necessary to bring it to the middle of the COLD CHECK band Perform a hot check at the first opportunity after the normal operating sump temperature of 71 C 93 C 160 F 200 F is reached Hot Check Procedure CAUTION The fluid must be hot to allow an accurate check The fluid level rises as temperature increases 1 Operate the transmission in D Drive until normal operating temperatures are reached Sump temperature 71 C 93 C 160 F 200 F Converter out temperature 82 C 104 C 180 F 220 F If the transmission temperature gauge is not present check fluid level when the engine water temperature gauge has stabilized 23 and the transmission has been operated under load for at least one hour 2 Park vehicle as follows a For vehicles containing 1000 and 2000 Product Family transmissions with park pawl 1 2 3 4 Bring the vehicle to a complete stop on a level surface using the service brake Make sure that the engine is at low idle rp
34. ge intervals 29 c Fluid Analysis Transmission protection and fluid change intervals can be optimized by monitoring fluid oxidation according to the tests and limits shown in Table 2 5 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 GN2055EN Technician s Guide for Automatic Transmission Fluid for additional information Table 2 5 Fluid Analysis Measurement Limits Viscosity 25 percent change from new fluid Total Acid Number 3 0 change from new fluid Ref SIL 17 TR 96 mg of potassium hydroxide KOH to neutralize a gram of fluid 2 8 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 not to exceed 0 2 percent will appear in the fluid during operation b Water Obvious water contamination of the transmission fluid or transmission fluid in the cooler 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 locate the correct source of cooler water contamination c Engine Coolant CAUTION Engine coolant in the transmission hydraulic system requires immediate action to prevent malfunction and
35. ies transmission dry weights are approximately 150 kg 330 Ib To help avoid personal injury and or property damage Use caution when installing removing or moving the transmission Get help when lifting the transmission Assistance from a hoist or another person may be required Make sure that the lifting equipment can properly support the transmission Use the following procedure to mount the transmission to the engine 1 Inspect the flexplate adapter if used for cracks or other damage and replace it when these conditions are found 2 Remove the torque converter retaining bracket just before the transmission is ready to be installed in the vehicle 56 3 Attach the flexplate adapter to the front of the torque converter or to the flexplate using six new adhesive coated M10 x 1 5 x 15 bolts Tighten each bolt to 57 68 N m 42 50 Ib ft 4 Align one of the flexplate s bolt holes with the access opening in the engine flywheel housing 5 Lubricate the center pilot boss with molybdenum disulfide grease Molycote G or equivalent 6 Install an M10 x 1 5 headless guide bolt into one of the flexplate bolt holes in the flexplate adapter or torque converter mounting lug refer to Figure 6 1 Align the guide bolt with the flexplate hole at the access opening FLYWHEEL HOUSING gt GUIDE BOLT Make from o X 1 5 bolt
36. inks and sharp bends Avoid routing the cable close to exhaust pipes or manifold The PTO harness must not rub or interfere with adjacent parts 2 Connect controls to the PTO 3 Check for proper PTO control operation 4 Couple the PTO output to its driven equipment Check couplings or 6 6 6 7 universal joints for correct assembly and alignment If the driven component is not a direct mount arrangement check the PTO drivelines for angularity phasing and offsets CONNECTING PARKING BRAKE CONTROL Connect and properly adjust the parking brake If present adjust the brake shoe to drum clearance as specified by the manufacturer CONNECTING COOLER Figure 6 2 shows typical cooler port locations on the transmission Consult AS64 071 in Allison Sales Tech Data Book on the Allison Extranet for cooler fitting torque values 59 MAIN PRESSURE TAP TO COOLER PORT FROM COOLER PORT BOTTOM VIEW V05742 01 Figure 6 2 Cooler Port Location 1 The transmission has a sump fluid thermistor on the pressure switch manifold Actual temperature readings may be viewed using the PC based diagnostic tool Consult the users manual furnished with the Allison DOC For PC Service Tool 2 A temperature gauge may be installed in the To Cooler line If equipped for them install a temperature probe capillary tube and bulb or a thermocouple a If e
37. is shown in Figure 5 3 a Measuring Equipment The following measuring equipment is required 600 mm 24 inch precision caliper 50 100 mm 2 4 inch telescoping gauge 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 No Housing 409 58 409 70 mm 16 125 16 130 inches No 2 Housing 447 68 447 81 mm 17 625 17 630 inches c Flywheel Housing Bore Runout Flywheel housing bore runout cannot exceed 0 51 mm 0 020 in TIR d Flywheel Housing Face Squareness The flywheel housing face cannot be out of square more than 0 51 mm 0 020 inch TIR e Crankshaft Hub Pilot or Adapter Diameter The crankshaft hub pilot or hub adapter pilot diameter must measure between 43 26 43 31 mm 1 703 1 705 inch f Crankshaft Hub Pilot or Adapter Squareness The crankshaft hub or hub adapter cannot be out of square more than 0 013 mm 0 0005 inch TIR per inch of diameter 46 LZ8S0A NIN 66170 90 ualdvav 10 4 NIN 0010 aad 0 06 66 6 1 1967 9067 L4IVHSYNVYO i d VW usidvav 65170 90
38. ith the engine running remove the dipstick from the tube and wipe clean 4 Insert the dipstick into the tube until it stops Then remove it Check fluid level reading Repeat the check procedure to verify the reading NOTE Safe operating level is within the HOT RUN band on the dipstick Figure 2 1 and Figure 2 2 The width of the HOT RUN band represents approximately 1 0 liter 1 06 quart of fluid at normal operating sump temperature 5 Ifthe 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 d 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 5 KEEPING FLUID CLEAN Prevent foreign material from entering the transmission by using clean containers fillers etc Lay the dipstick in a clean place while filling the transmission CAUTION Containers or fillers that have been used for antifreeze solution or engine coolant must NEVER be used for transmission fluid Antifreeze and coolant solutions contain ethylene glycol which if put into the transmission can cause the clutch plates to fail 2 6 FLUID RECOMMEND
39. l J4VHS 1 00 00 25660 HOLNID Old HO T33HM 3NOL NOLLONS JINGOW 1 NIYIN 10H1NO2 JINON 3A1VA 109109 wes NVd 110 4320 AdV13NVld 4 AYVLANV1d Zd AYVLANV 1d d LAVHS LAdLNO YOSNAS 03246 LNdLNO 43409 JINON 43409 uV3H NIVIN 46 1 19 3857 u3183ANO2 HOLNID 50 qaads SNOYOL HOLNTD LYOddNS 11083 HOLNTD 29 YOSNAS 03385 LNdNI FINGOW ONISNOH YALYSANOD JINON LYOddNS LNOYS ONISNOH YALYSANOO Figure 1 2 2000 Product Family Cross Section LAVHS SNIGHNL H LNT LIe HOLNTD NOILONS Old HO 133HM 01 3 FINGOW H LNTO SNILVLOY 00 00 SSE60A FINGOW SATIVA 1OULNOD NVd 110 d33d AYVLANV 1d Ld AYVLANV1d d 1 LAVHS 104100 YOSNAS 03345 104100 0 FINGOW 43409 ual NIVIN 1 3183ANO9 1 HOLNTD S2 HOLNTD 9 NIYIN FINGOW ONISNOH NIV YOSNAS 03345 1 1804405 11093 uOSN3S 03348 LNdNI e SNISNOH H3183ANOO FINGOW LYOddNS LNOYS ONISNOH H31H3ANO9 Figure 1 3 2000 Product Family
40. ll remain on steady at all times continuing to operate in this manner until service is performed and the indicator is reset If reset does not occur within 100 hours the CHECK TRANS light will be illuminated in addition to the TRANS SERVICE light and the TCM will register a diagnostic code The indicator will reset automatically upon elimination of the clutch clearance condition which initiated it The indicator can also be reset using the Allison DOC For PC Service Tool if necessary The Allison DOC For PC Service Tool may be used to display the amount of transmission operation from the initial service indication until the service reset 2 3 IMPORTANCE OF PROPER TRANSMISSION FLUID LEVEL Transmission fluid cools lubricates and transmits hydraulic power Always maintain proper fluid level If fluid level is too low the torque converter and clutches do not receive an adequate supply of fluid and the transmission overheats If the level is too high the fluid aerates causing the transmission to shift erratically and overheat Fluid may be expelled through the breather or dipstick tube when the fluid level is too high 2 4 TRANSMISSION FLUID CHECK WARNING For vehicles containing 1000 and 2000 Product Families transmissions with park pawl each time you park the vehicle or leave the operator s station with the engine running do the following Bring the vehicle to a complete stop using the service brake Make sure th
41. ls and take any other steps necessary to keep the vehicle from moving b For vehicles containing 2000 Product Family transmissions with auto apply parking brakes 1 Bring the vehicle to a complete stop a level surface using the service brake 2 3 Make sure that the engine is at low idle rpm Put the transmission in PB Auto Apply Parking Brake Make sure that the parking brake is properly engaged 4 Apply the emergency brake if present and make sure it is properly engaged 22 5 Chock the wheels and take any other steps necessary to keep the vehicle from moving c For vehicles containing 2000 Product Family transmissions without auto apply parking brakes 1 Bring the vehicle to a complete stop on a level surface using the service brake 2 Make sure that the engine is at low idle rpm 3 Put the transmission in N Neutral 4 Apply the emergency brake and or parking brake and make sure they are properly engaged 5 Chock the wheels and take any other steps necessary to keep the vehicle from moving Run the engine for at least one minute Apply the service brakes and shift to D Drive then to N Neutral and then shift to R Reverse to fill the hydraulic system Finally shift to P Park or PB Auto Apply Parking Brake if available or N Neutral and allow the engine to idle 500 800 rpm Slowly release the service brakes With the engine runnin
42. m Put the transmission in P Park If a parking brake is present apply the parking brake Make sure that the parking brake is properly engaged Engage the P Park range by slowly releasing the service brake Apply the emergency brake if present and make sure it is properly engaged Chock the wheels and take any other steps necessary to keep the vehicle from moving b For vehicles containing 2000 Product Family transmissions with auto apply parking brakes 1 2 3 4 5 gt wm Bring the vehicle to a complete stop a level surface using the service brake Make sure that the engine is at low idle rpm Put the transmission in PB Auto Apply Parking Brake Make sure that the parking brake is properly engaged Apply the emergency brake if present and make sure it is properly engaged Chock the wheels and take any other steps necessary to keep the vehicle from moving c For vehicles containing 2000 Product Family transmissions without auto apply parking brakes 1 2 3 4 Bring the vehicle to a complete stop on a level surface using the service brake Make sure that the engine is at low idle rpm Put the transmission in N Neutral Apply the emergency brake and or parking brake and make sure they are properly engaged 24 5 Chock the wheels and take any other steps necessary to keep the vehicle from moving 3 W
43. manufacturers requirements d Connect PTO Lube if required Some PTOs require pressure lubrication When needed tap into the cooler return fitting or line at the transmission converter housing refer to Figure 4 1 PTO lubrication There is only one acceptable use of transmission main pressure for accessories that being to control engagement of the PTO clutch This practice is permitted for this function only because there is no flow the fluid is deadheaded NOTE It is not acceptable to use the transmission main pressure for An orifice of 0 81 mm 0 032 inch must be present in the line to control the amount of fluid diverted from the transmission Some PTO assemblies contain internal restrictions equivalent to the required orifice check with the PTO manufacturer for lubrication needs and the orifice installation This connection can be made later if the lube line will interfere with transmission installation Refer to Figure 4 2 which shows this connection schematically 39 MAIN PRESSURE TAP NN TO COOLER PORT FROM COOLER PORT BOTTOM VIEW V05742 01 Figure 4 1 Cooler Port and Main Pressure Tap Location 40 FROM COOLER PORT PTO LUBE LINE with 0 81 mm 0 032 in orifice COOLER RETURN OIL LINE ENLARGED DETAIL 05816 Figure 4 2 PTO Lube Plumbing Schematic 41 EXHAUST TO
44. missions without auto apply parking brakes each time you park the vehicle or leave the operator s station with the engine running do the following 1 Bring the vehicle to a complete stop using the service brake 2 Make sure that the engine is at low idle rpm 3 4 Apply the emergency brake and or parking brake and make Put the transmission in N Neutral sure it is properly engaged If the operator s station will be unoccupied with the engine running chock the wheels and take any other steps necessary to keep the vehicle from moving If this procedure is not followed the vehicle can move suddenly and you or others could be injured NOTE For accurate fluid level checks be sure that the fill tube and dipstick meet Allison Transmission specifications Requirements for the short and medium fill tube and dipstick are shown in Figure 2 1 the long fill tube and dipstick are shown in Figure 2 2 When checking a short or medium dipstick calibration 1 Remove the oil pan 2 Take measurements from the oil pan splitline When checking a long dipstick calibration 1 Be sure the dipstick contacts the oil pan surface as shown in Figure 2 2 2 Take measurements from the end of the dipstick 00 10 70850 5 LHSIY 5 1391 NVd QHVGNVIS MOTIVHS NVd GYVGNVLS MOTIVHS a NVd QuvaNvis a NVd QuvaNvis NVd MOTIVHS NYd MOTIVHS
45. mm M required Clamp must positively lock in cable groove HITCH PIN CLIP 30 2 mm 1 19 in Fuel lever attachment linkage or bracket mustt allow fuel lever to return to closed throttle positionn when sensor rod is maintained at full throttle position ENGINE FUEL LEVER Attach the throttle sensor directly to the engine fuel lever with no breakover or yield linkages between theg engine fuel lever shaft and the attachment point of theg throttle sensor CLOSED THROTTLE 183 1 mm 7 21 in 3 FULL THROTTLE SAME AS WITHOUT 160 2 mm 6 31 in MIN SLIP LINK FULLY EXTENDED CECECE CE 38 1 mm 1 50 in lt lt gt gt FULLY 7 OPTIONAL THROTTLE SENSOR ASSEMBLY WITH SLIP LINKO HITCH PIN CLIP V00430 06 Figure 5 4 Hitch Pin Throttle Position Sensor Installation Diagram 54 c Hitch Pin Throttle Position Sensor Installation 1 Install the throttle sensor body as follows a b 6 Clamp cable end using clamp and shims Figure 5 4 Secure the sensor body using the mounting holes provided Install a heat shield if any part of the throttle sensor is near the exhaust manifold turbochargers or any other heat source 2 Adjust the throttle sensor as follows a b 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 c
46. nd the transmission containing 100 percent of Allison approved TES 295 fluid For transmissions that contain a mixture of Allison approved TES 295 fluid and non approved fluids refer to Table 2 2 NOTE Fluid Exchanging Machines are not recommended or recognized due to variation and inconsistencies that may not guarantee removal of 100 percent of the used fluid Table 2 2 through Table 2 3 Recommended Fluid Filter Change Intervals is a general guide for fluid and filter change intervals Allison Transmission requires an initial filter change for the Spin On Control Main Filter during the first 5000 miles 8000 km or 200 hours whichever comes first Refer to the Recommended Fluid and Filter Change Intervals schedules for recommendations The transmission sump filter is permanent and does not require replacement except at overhaul Severe Vocations include armored car automobile transporter beverage delivery food distribution general freight line haul livestock hauler moving storage one way rental truck recycling short haul LTL and pick up and delivery Highway Series models are also acceptable for poultry bus applications when truck chassis are utilized General Vocations include all other vocations Local conditions severity of operation or duty cycle may 27 require more or less frequent fluid change intervals that differ from the published recommended fluid change intervals of Allison Transmission The following
47. nout 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 Sales Tech Data Book on the Allison Extranet NOTE DO NOT use sealing compounds they are usually incompatible with automatic transmission fluid 38 a Install Guide Pins Guide pins are included in the PTO manufacturers installation kit Determine the required position of the guide pins in relation to the mounted position of the PTO Install two headless guide pins into the main housing PTO pad Tighten the pins b Install Gasket Install the special gasket over the guide pins ribbed surface away from the transmission c Mount the PTO CAUTION M10 bolts must be used to attach the PTO to the transmission Inch series threads 0 375 16 UNC will damage the transmission main housing Mount the PTO on the guide pins or studs provided in the PTO kit Mesh 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 and nuts if used When nuts are not used two bolts replace the guide pins Tighten all bolts to 57 68 N m 42 50 Ib ft Tighten nuts to manufacturers specifications Be sure that the PTO backlash meets
48. nspect the exterior of the transmission at regular intervals Severity of service and operating conditions determine the frequency of these inspections Inspect the transmission for Loose bolts transmission and mounting components Fluid leaks repair immediately Loose dirty or improperly adjusted throttle sensor Damaged or loose hoses Worn frayed or improperly routed electrical harnesses Worn or frayed electrical connectors Worn or out of phase driveline U joints and slip fittings Clogged or dirty breather vent assembly 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 DO NOT WELD on the vehicle without disconnecting TCM battery power and ground leads DO NOT WELD on any control components DO NOT CONNECT welding cables to any control components A label describing on vehicle welding precautions 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 PROGNOSTICS a 1000 and 2000 Product Families Service Progn
49. olts have been installed and tightened finger tight 13 Rotate the engine crankshaft to install the remaining new adhesive coated bolts into the flexplate adapter After all bolts have been installed finger tight tighten the bolts to 57 68 N m 42 50 Ib ft 14 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 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 58 6 5 CONNECTING POWER TAKE OFF CONTROLS If not already mounted mount the PTO s onto the transmission refer to 4 3 NSTALLING PTO CAUTION PTO units using transmission main pressure to engage the PTO gear must have a positive main pressure shut off at the solenoid valve when the PTO is not engaged Failure to provide this feature may cause inadvertent clutch apply and PTO damage Check the PTO harness routing for k
50. on continuing to flash for two minutes after the selection of D Drive each time until service is performed and the indicator is reset The TRANS SERVICE indicator can be reset with the Allison DOC For PC Service Tool It may also be reset by selecting N R N R N D N on the shift selector pausing briefly less than 3 seconds between each selector movement with the ignition on and the engine not running More details are provided in applicable Allison service literature for your specific transmission model Failure to perform maintenance and reset the TRANS SERVICE indicator after an additional 100 hours of transmission operation will result in the illumination of the CHECK TRANS light in addition to the TRANS SERVICE light Any time this light is illuminated the TCM will register a diagnostic code which will require the use of Allison DOC For PC Service Tool to clear the code In addition to viewing diagnostic codes the Allison DOC For PC Service Tool may also be used to display the amount of transmission operation from the initial service indication until the service reset d Transmission Health Monitor The TRANS SERVICE indicator will be illuminated indicating the need for clutch maintenance when the remaining clutch life reaches approximately 10 percent or if the running clearance exceeds a maximum value which may indicate a non wear related issue The indicator will be lit steadily upon initialization of the TCM and wi
51. ostics Service prognostics will be available beginning with MY09 vehicles and is only offered as a package at the option of the OEM refer to the caution for vehicles not equipped for Prognostics The Service Prognostics package requires the use of Allison approved TES 295 fluids and P N 29539579 Control Main filter Prognostics are used to predict the need for transmission maintenance Transmission operating parameters monitored by the prognostics feature are 1 Oil Life Monitor 2 Filter Life Monitor 3 Transmission Health Monitor NOTE To determine if your vehicle has Prognostics enabled observe operation of the OEM installed service indicator light This light will illuminate for five seconds during start up in all equipped vehicles When prognostics are enabled the service indicator light will illuminate again for three seconds after the initial five second bulb check If you are still unable to determine whether your vehicle has Prognostics enabled consult with your OEM service department or an authorized Allison distributor or dealer When a specified service threshold is detected for one of these parameters the TRANS SERVICE indicator is illuminated to alert the operator to the need for action Failure to attend to the service condition and reset the TRANS SERVICE indicator within a defined operating period will result in the illumination of the CHECK TRANS light in addition to the TRANS SERVICE light indicating the increa
52. quipped with a capillary tube and bulb 1 Tighten the adapter tight enough to prevent leakage 2 Install the bulb into the adapter and tighten the nut 3 Check the capillary tube for interference with other parts that might chafe or damage the tube Long tubes may require support clips or brackets b If equipped with a thermocouple 1 Install the thermocouple and connect the leads 6 8 CONNECTING CONTROLS 1 Remove any protective covering from the wiring harness connectors Connect the external wiring harness to the main electrical connector and the engine turbine and output speed sensors Figure 1 4 and Figure 1 5 Keep dirt and debris out of the connector 60 2 If PTO s is are used connect the PTO s wiring harness es The PTO connector is NOT part of the Allison Transmission external wiring harness 3 Connect linkage to the transmission shift lever For information on adjusting the shift linkage refer to the SHIFT SELECTOR CABLE LINKAGE section of the In Chassis Maintenance guide GN4008EN 4 If used connect wire s to electric tachograph 5 Make sure that the speed sensors the PTO connector and all other connectors are securely seated and latched A connector can be heard or felt when it latches but confirm the latching by pulling on the connector NOT THE WIRES 6 If parking brake is present connect linkage 6 9 FILLING HYDRAULIC SYSTEM 1 Check that all unused hydraulic openings are plugg
53. r yoke to the replacement transmission The output flange or yoke is retained by 15 20 x 2 inch flanged head bolt 36 TRANSMISSION PREPARATION Section IV 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 or raised metal that prevents free entry into the crankshaft hub or adapter c Starter Ring Gear Check the starter ring gear for excessive wear or damage d Transmission Mounting Flange Check the transmission mounting flange for raised metal dirt or if used pieces of gasket material e Transmission to Engine Mounting Inspect 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 GN4008EN In Chassis Maintenance for replacement instructions If not replacing the oil seal lubricate it with high temperature grease or transmission fluid CAUTION DO NOT attempt to polish the oil seal contact surface on the flange or yoke Scratches or machine type lead can cause
54. rect any faulty conditions Shift selector improper operation poor electrical connections improper harness routing Cab and chassis wiring harness poor electrical connections frayed insulation wiring damage Throttle sensor components if present freedom of movement improper routing bellows damage improper or loose cable mounting 52 PTO controls if present damage wear improper operation lubrication electrical harness connections and wiring damage Temperature gauge capillary tube damage if used sensor damage Fluid pressure gauge tubing damage kinks improper routing b Throttle Position Sensor TPS Adjustment Using Diagnostic Tool When properly installed by the equipment manufacturer the TPS if used should not require adjustment If TPS adjustment is necessary confirm that it has been installed to Allison Transmission specification refer to Figure 5 4 The TPS is self calibrating and therefore has no optimum closed throttle or full throttle value Be sure there is no misalignment or obstruction to smooth movement through the full stroke of the TPS The Allison DOC For PC Service Tool Windows based interface software diagnostic tool can be used to verify the TPS adjustment 0 percent at closed throttle and 100 percent at full throttle See the users manual that comes with the diagnostic tool for details Also be sure
55. roduct Families Service Manual SM3191EN for detailed transmission service and maintenance instructions c Road Test Checklist Complete the following checklist Instruments CHECK TRANS Check Transmission light Speedometer Transmission fluid pressure gauge if used Temperature gauge if used Reverse warning system if used Transmission Fluid Fluid level meets specifications cold neutral level No leaks Warm up and check fluid level hot neutral level No Load Governed Engine Speed No load governed speed of engine Adjust governor as to the manufacturer s specifications for the engine transmission being tested installed PTO operation refer to the latest edition of the applicable Operator s Manual refer to 7 2 SERVICE LITERATURE Shift Sequence Transmission upshifts and downshifts smoothly through all ranges Other Checks Stall test must only be performed by qualified service technician Shift quality 64 Comments 65 CUSTOMER Section VII SERVICE 7 1 OWNER ASSISTANCE There are distributors and dealers around the world ready to stand behind every Allison Transmission product Any situation that arises in connection with the sale operation or service of your transmission will be handled by the distributor or dealer in your area Refer to the Worldwide Sales and Service Directory SA2229
56. s Savers 120 000 km 80 000 km Overhaul 80 000 km 36 months 24 months 24 months 3000 hours 2000 hours 2000 hours Control Main Spin on Filter Only lnitial 10 000 miles 16 000 km o 400 hours whichever comes first Table 2 4 Schedule 3 Recommended Fluid and Filter Change Intervals Allison A o ON Beginning in MY09 Vocation Main Lube Auxiliary Change Change fluid when filer when Change filter when indicated by controller or 48 months whichever comes first indicated by indicated by controller or controller or Overhaul 48 months 48 months whichever whichever comes first comes first General or Severe Allison Prognostics must only be used with Allison approved TES 295 fluid Allison Prognostics must only be used with Allison P N 29539579 control main spin on filter Control Main Spin on Filters Only lInitial 10 000 miles 16 000 km or 400 hours whichever comes first b Abnormal Conditions Transmissions used in high duty cycle applications should use fluid analysis to be certain that a proper fluid change interval is established Transmission fluid must be changed whenever there is evidence of dirt or a high temperature condition A high temperature condition is indicated by the transmission fluid being discolored or having a strong odor or by fluid analysis Local conditions severity of operation or duty cycle may require more or less frequent fluid or filter chan
57. sed probability that the service condition may will develop into a more serious condition The process for resetting the TRANS SERVICE indicator varies for each feature and is described in each of the following sections The Allison DOC For PC Service Tool may be used to review the current status of any of these features and a history of indicator resets CAUTION Transmission Prognostics features may be turned ON or OFF by a special transmission calibration and REQUIRES the use of Allison approved TES 295 fluids If any other fluids or filters are used prognostic features must be turned OFF Prognostics information will not be accurate with any the use of any other transmission fluids and could result in improper maintenance activities resulting in transmission damage If Prognostics is not programmed or is turned OFF refer to the miles hours months fluid and filter change interval charts in the section of this book or visit www allisontransmission com for a list of Allison approved TES 295 fluids or read Service Tips 1099H for details b Oil Life Monitor The TRANS SERVICE indicator will be illuminated denoting a required change of the transmission fluid when the remaining fluid life reaches approximately 2 percent the parameter begins at 100 percent moving downward towards the lowest threshold The TRANS SERVICE indicator will be lit steadily upon each initialization of the TCM and will remain on steady for approximately t
58. t 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 Check Transmission light should come on c Start the engine d The CHECK TRANS Check Transmission light should go off 3 Clear Trouble Codes during installation it is common for false codes to be stored in the electronic controls TCM These codes must be cleared prior to road testing the vehicle Refer to the Allison DOC For PC Service Tool User s Guide GN3433EN for details 4 Road Test the Vehicle allow the electronic control time to converge shifts 5 Check for Proper Operation check all components for proper mounting and operation and check for transmission fluid leaks at gasket surfaces lines and hoses 6 Recheck for Trouble Code use the Allison DOC for PC Service Tool or shift selector to determine if codes were set during the road 63 test Refer to the Allison DOC For PC Service Tool User s Guide GN3433EN for details 7 Troubleshoot if codes exist after the road test problems must be found and corrected refer to TS3977EN 1000 and 2000 Product Families Troubleshooting Manual b Service and Maintenance Following an initial unit exchange program refer to the 1000 and 2000 P
59. to check for diagnostic codes DTCs associated with TPS function 53 BENDING LOAD APPLIED DY UNACCEPTABLE INSTALLATION MOUNTING PROVISION Use M6 x 1 00 or 14 20 in series bolts 3 places Torque M6 x 1 00 bolt to 10 13 Nem 84 120 Ib in Torque 1 20 in series bolts to 13 14 Nem 108 132 Ib iy Mount to a solid frame member Flatness oft chassis mounting surface must not exceed 0 8 mm 0 03 in 10 07 MAX INSTALLED OPERATING ANGLE 0 IN ALL DIRECTIONS LOADING INO TENSION ONLY ACCEPTABLE INSTALLATION Attachment must provide freedom of motion to allow cable loading ind tension only no bending loads WIRING HARNESS 55 0 mm 2 17 MIN REQUIRED Fuel control must not mov FOR CONNECTION the throttle sensor beyond 152 0 mm 6 00 REMOVAL the closed throttle positionn ALLOWANCE RADIUS at any time FULLY EXTENDEI FORCE REQUIRED 26 7 N 6 0 LB MAX FULLY RETRACTED MOUNTING LENGTH CLOSED THROTTLE NOTE Mounting lengt 95 2 mm 3 75 in 50 8 mm 2 inches equals cable length 47 5 mm 1 87 in FULL THROTTLE 118 1 mm 4 65 in OPERATING BAND 15 2 22 9 mmi 0 6 09 in The location of then clamping bracket relativel to the fuel lever at closed throttle must be maintained within this range Attach to engine or 93 45 mm 3 679 in housing using clamp and shims as 87 15
60. wo minutes after the initial selection of a drive range until service is performed and the indicator is reset The TRANS SERVICE indicator can be reset with the Allison DOC For PC Service Tool It may also be reset by selecting N D N D N R N on the shift selector pausing briefly less than 3 seconds between each selector movement with the ignition on and the engine not running More details are provided in applicable Allison service literature for your specific transmission model Failure to perform maintenance and reset the TRANS SERVICE indicator within the next 100 hours of transmission operation will result in the illumination of the TRANS SERVICE light in addition to the TRANS SERVICE light Any time this light is illuminated the TCM will register a diagnostic code which will require the use of Allison DOC For PC Service Tool to clear the code In addition to viewing diagnostic codes the Allison DOC For PC Service Tool may also be used to display the amount of transmission operation from the initial service indication until the service reset c Filter Life Monitor The TRANS SERVICE indicator will flash beginning with the first TCM initialization after reaching the time and mileage parameters indicating that the filter has reached the end of its designed life The indicator will continue to flash for two minutes after D Drive has been selected Thereafter the indicator will illuminate and flash upon each TCM initializati
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