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In-Chassis Maintenance 1000 And 2000 Product Families Allison

1. NUT 29520052 M10 x 1 5 metric mt ui Torque to 20 27 Nem not supplied with transmission Hold the selector lever to C AL avoid internal damage while tightening the nut TRANSMISSION Do not use power impact wrench to torque PARK PAWL APPLY R REVERSE N NEUTRAL 23 2 OD OVERDRIVE Ranges E pe 1 5 where 5th is overdrive D DRIVE Ranges 1 4 SELECTOR SHAFT FLATS AS SHOWN INDICATE PARK POSITION 1000 AND 2000 PRODUCT FAMILIES WITH PARK PAWL 20 9 gt Only used on vehicles with automatic park brake apply system SELECTOR SHAFT FLATS AS SHOWN INDICATE PARK BRAKE APPLY POSITION 2000 PRODUCT FAMILY WITHOUT PARK PAWL V05807 00 02 Figure 3 6 Transmission Shift Lever Positions 40 V09457 00 00 Figure 3 7 Transmission Main Electrical Connector Remove the oil pan and oil pan gasket Inspect the magnet in the oil pan refer to Figure 6 6 Be sure that excessive or large metallic particles are not present These conditions would indicate that an overhaul may be required Remove the suction filter by pulling straight down where the suction tube is seated in the main housing Remove the suction seal from the filter or from the seal bore in the main housing Discard the old seal and the filter if it is being replaced Disconnect the external wiring harness from the main transmission electrical connector NOTE The transmission main e
2. NOTE When the transmission is turned vertically with the torque converter end up the fluid will drain out of the rear cover Make provisions to collect this drainage of fluid 2 Position the transmission vertically with the torque converter end up NOTE Before the torque converter is separated from the transmission measure the distance from the torque converter mounting lugs to the transmission mounting face This is an important measurement that is required during installation to confirm that the torque converter has been installed to correct depth for proper engagement 73 3 Take the measurement described in the NOTE above 4 Attach a three strand sling to the torque converter Lift the torque converter from the transmission and set it safely aside until needed at assembly NOTE Before removing the seal observe the direction the lip of the J seal is pointing inward toward the bushing with the enclosed face visible there may be a part number visible on this face During installation the seal must be installed in this orientation to seal effectively 5 Obtain special tool J 24171 A and install the tip with a 90 degree hook onto the end of the slide hammer 6 Position the 90 degree hook behind the rear face of the seal outer case G refer to Figure 6 14 FRONT SEAL b om OUTER CASE EN L rds J 24171 A SPECIAL TOOL Figure 6 14 Front Seal Removal 7 Remove the front
3. Replace flange When replacing seal refer to 6 6 REAR SEAL REPLACEMENT Replace output bolt sealing washer Replace and or torque output flange bolts refer to Section 6 1 OUTPUT FLANGE YOKE REPLACEMENT Replace front seal refer to Section 6 10 FRONT SEAL REPLACEMENT Verify bolt torque Replace manifold gasket seal refer to COOLER MANIFOLD GASKET Verify bolt torque Replace bolt seals Inspect for cracked converter lugs converter cover or converter housing porosity replace converter refer to Service Manual SM4006EN ST Table 1 1 Problem LEAKING FLUID TRANSMISSION INPUT cont d DIRTY FLUID Troubleshooting Performance Complaints cont d Possible Cause Spin on filter leaking Main pressure plug leak Pump bushing shows excessive wear Failure to change fluid and filters Excessive heat Substandard fluid Clutch transmission failure Suggested Remedy Replace filter Replace or torque main pressure plug Rebuild and repair pump Check adaption Change fluid and install new filters refer to Mechanic s Tips MT4007EN Inspect and test cooling system for restrictions and proper capacity Use recommended fluid refer to Mechanic s Tips MT4007EN Overhaul transmission refer to Service Manual SM4006EN 1 3 TRANSMISSION STALL TEST AND NEUTRAL COOL DOWN TEST a Purpose Stall testing is performed to determine if a vehicle performance complaint is due to an engine or transmissi
4. Allison Transmission NN N NW N QA Y N w PAA SN m N 22 D E N Y A Y Y N N YIN AVS 22 2 Allison 4 Generation Controls In Chassis Maintenance 1000 And 2000 Product Families GN4008EN BECER 2007 JANUARY Eaa laag GNaoosEN Allison Transmission Allison 4th Generation Controls 1000 Product Family 2000 Product Family Allison Transmission Allison Transmission Inc P O Box 894 Indianapolis Indiana 46206 0894 www allisontransmission com Printed in USA Copyright O 2007 Allison Transmission Inc NOTES TABLE OF CONTENTS SECTION TROUBLESHOOTING 1 1 GENERAL TROUBLESHOOTING INFORMATION 7 1 2 GENERAL TROUBLESHOOTING OF PERFORMANCE COMPLAINTS 10 1 3 TRANSMISSION STALL TEST AND NEUTRAL COOL DOWN TEST 26 1 4 PRESSURE SCHEDULE VERIFICATION 31 SECTION FLUID LEAK DIAGNOSIS 2 FINDING THE LEAK a casse PEE RE RU REAPER d Res 32 SECTION Ill SHIFT SELECTOR CABLE LINKAGE 3 1 SHIFT SELECTOR AND CABLE LINKAGE 35 3 2 INTERNAL MODE SWITCH IMS 39 SECTION IV SELECTOR SHAFT SEAL REPLACEMENT 4 4 REMOVAL CRX WE ud 46 4 2 INSTALLATION iocis EXTR a 46 SECTION V PARKING BRAKE 5 1 ADJUSTMENT ue e RR EO UR ERR e hs 49 5 2 REPLACEMENT S s sss doe ser
5. For PC Service Tool to determine if DTC is present Replace relay or repair circuit Measure input power to the TCM and correct if necessary Repair vehicle wiring Repair wiring Repair ground circuit Repair Circuit 129 I Table 1 1 Problem NO CHECK TRANS LIGHT AT IGNITION TRANSMISSION WILL NOT SHIFT TO FORWARD OR REVERSE STAYS IN NEUTRAL Troubleshooting Performance Complaints cont d Possible Cause Faulty light bulb or socket Incorrect wiring to and from CHECK TRANS light bulb Faulty vehicle wiring Circuit 129 open Engine rpm too high Low fluid level Throttle position sensor or linkage is not functioning properly Faulty throttle signal from engine Shift selector is not functioning properly Speed sensor s not functioning properly Mechanical failure to C5 clutch Mechanical failure in transmission torque converter shafts or planetaries Low main pressure Faulty wiring in TCM Input Output function circuits Suggested Remedy Replace light bulb or socket Repair wiring refer to Troubleshooting Manual TS3977EN Appendix E Repair vehicle wiring Repair Circuit 129 Reduce engine rpm it may be necessary to reselect N Neutral also and then D Drive or R Reverse Add fluid to correct level refer to Mechanic s Tips MT4007EN Refer to Mechanic s Tips MT4007EN Correct engine throttle signal Repair shift selector or adjust linkage Repair or replace speed sensor s
6. replace the shift selector 4 Reconnect all components properly adjust and be sure that normal function has been restored 38 SELECTOR LEVER HELD IN NEUTRAL BY TRANSMISSION DETENT CABLE JAM NUT Rotate pivot on threaded end of cable until it is aligned with hole in selector lever Verify free pin fit between pivot and selector lever Install lock pin and torque jam nut if present to 8 5 N m 75 in Ib V09465 00 01 Figure 3 5 Proper Shift Selector Cable Adjustment 3 2 INTERNAL MODE SWITCH IMS a Adjustment The Internal Mode Switch IMS does not require adjustment The IMS engagement pin located on the detent spring provides proper alignment between the IMS and the detent lever Use the following procedure when diagnostic trouble codes have been logged and the corrective action is to replace the IMS switch b Replacement during the replacement of the IMS Fluid in good condition drained into NOTE It would be helpful to know how much transmission fluid is lost a clean container may be reused 1 Remove the drain plug and sealing washer from the oil pan and allow the fluid to drain into a suitable container refer to Figure 6 6 Examine the fluid as described in Mechanic s Tips MT4007EN 2 Remove the 12 bolts that fasten the oil pan to the main housing Hold the oil pan in position as the last bolt is removed 39 Selector shaft lever against shoulder on shaft
7. Make sure the engine air induction system and exhaust system have no restrictions 6 Perform a cold check of the transmission fluid level and adjust as necessary 7 Connect the Allison DOC For Tool to the vehicle diagnostic data connector or install an accurate tachometer do not rely on the vehicle tachometer 8 Install a temperature gauge with the probe in the transmission converter out to cooler line Allison DOC For PC Service Tool displays sump temperature only 9 Install wheel chocks 26 10 Find a competent operator to assist at the vehicle controls 11 Be sure the vehicle brakes are fully locked WARNING To help avoid personal injury such as burns from hot transmission fluid and or to help avoid equipment damage do not stall the torque converter for more than ten seconds maximum and monitor transmission fluid temperature Immediately return the engine to idle if converter out to cooler temperature exceeds 150 C 300 F Operating the transmission at high engine power at transmission stall or near stall conditions causes a rapid rise in the transmission fluid temperature The fluid in the transmission torque converter is absorbing all of the engine power and the vehicle cooling system cannot dissipate the excessive heat load Extended operation under high heat load conditions causes transmission and cooling system damage and may cause hydraulic lines to fail causing high temperature flui
8. PCS2 SS2 SS3 or TCC Use the following procedure to replace any solenoid except Shift Solenoid 1 SS1 and Main Mod NOTE It would be helpful to know how much transmission fluid is lost during the replacement of any solenoid Fluid in good condition caught in a clean container may be reused Remove the drain plug and sealing washer from the oil pan and allow the fluid to drain into a suitable container refer to Figure 6 6 Examine the fluid as described in MT4007EN Remove the 12 bolts that fasten the oil pan to the main housing Hold the oil pan in position as the last bolt is removed Remove the oil pan and oil pan gasket Inspect the magnet in the oil pan refer to Figure 6 6 Be sure that excessive or large metallic particles are not present These conditions would indicate that an overhaul may be required Remove the suction filter by pulling straight down where the suction tube is seated in the main housing 68 SIX SPEED TUBE CONNECTOR PRESSURE SWITCH REVERSE SIGNAL TUBE MANIFOLD ASSEMBLY V05791 03 00 Figure 6 11 Pressure Switch Manifold Assembly Replacement 5 Remove the suction seal from the filter or from the seal bore in the main housing Discard the old seal and the filter if it is being replaced 6 Disconnect the internal wiring harness from the solenoid being changed NOTE When the PCS1 and PCS2 solenoid retaining bracket is J removed there are two sets
9. Service Manual SM4006EN Repair or replace solenoids refer to Section 6 9 CONTROL VALVE COMPONENT REPLACEMENT Replace Main Mod solenoid refer to Service Manual SM4006EN Test spring and replace if necessary refer to Service Manual SM4006EN Replace or rebuild control valve assembly Care should be taken when removing and labeling shift springs refer to Service Manual SM4006EN Repair or replace gauge 0c Table 1 1 Problem A Low or No Main Pressure in All Ranges cont d B Low Main Pressure in Specific Ranges Normal Pressure in Other Ranges Troubleshooting Performance Complaints cont d Possible Cause Worn or damaged oil pump Leak in suction circuit Seal leak Suggested Remedy Replace or rebuild oil pump refer to Service Manual SM4006EN Inspect suction circuit for leaking seal gasket or mating surface Refer to Service Manual SM4006EN ABNORMAL STALL SPEEDS Stall In First Range Fifth Range A High Stall Speeds B Low Stall Speeds Not in gear Low fluid level aerated fluid Faulty torque converter Incorrect torque converter Clutch pressure low Clutch slipping use the Allison DOC to determine turbine speed Higher power engine Engine not performing efficiently may be due to plugged or restricted injectors high altitude conditions dirty air filters out of time throttle linkage electronic engine controls problem Select D Drive Add fluid to
10. as necessary refer to Service Manual SM4006EN Inspect control module gasket C1 clutch plates piston and rotating seals replace rebuild as necessary refer to Service Manual SM4006EN Inspect C2 clutch plates piston and rotating seals replace rebuild as necessary refer to Service Manual SM4006EN Inspect C3 clutch plates and piston seals replace rebuild as necessary refer to Service Manual SM4006EN Inspect C4 clutch plates and piston seals replace rebuild as necessary refer to Service Manual SM4006EN 61 Table 1 1 Problem E Ranges 1 R Only A Low or No Main Pressure in All Ranges Troubleshooting Performance Complaints cont d Possible Cause C5 clutch slipping leaks at piston seals C5 clutch plates worn LOW PRESSURE SECTION Incorrect fluid level Clogged or faulty oil filter element Main pressure regulator valve sticking Leaking solenoids in control valve assembly Main Mod solenoid failure Weak broken or missing main pressure regulator valve spring Control valve body leakage separator plate not flat loose control valve body bolts Faulty or incorrect fluid pressure gauge Suggested Remedy Inspect C5 clutch plates and piston seals replace rebuild as necessary refer to Service Manual SM4006EN Correct fluid level refer to Mechanic s Tips MT4007EN Replace oil filter refer to SUCTION FILTER AND SEAL REPLACEMENT Overhaul front support assembly refer to
11. hold it into position Start the remaining four bolts in recessed locations and one longer gold colored bolt and tighten them all by hand Torque the bolts to 10 13 Nem 7 10 Ib ft 67 9 10 Connect the internal wiring harness connector to the pressure switch manifold assembly Place a new seal on the suction filter tube The seal should locate against a shoulder on the suction filter tube Push the filter and seal into the seal bore in the main housing Be sure the suction filter is properly positioned Be sure that all gasket material is removed from the main housing and there are no scratches that would cause a splitline leak Install two headless guide bolts M8 x 1 25 into opposite corners of the oil pan mounting face on the main housing Place a gasket on the oil pan and align the bolt holes Slide the oil pan gasket and oil pan over the guide bolts and hold them in place while installing two of the bolts to hold the parts in place Install the remainder of the 12 bolts that fasten the oil pan to the main housing two will replace the guide bolts Tighten the bolts to 24 29 Nem 18 21 Ib ft Install the drain plug and sealing washer Tighten the drain plug to 30 40 N m 22 30 Ib ft Replace the quantity of transmission fluid lost during the pressure switch manifold assembly replacement process Refer to MT4007EN for fluid check procedures Solenoid Replacement PCS1
12. housings have a removable cooler manifold Use the following procedure to replace the cooler manifold gaskets a Removal Refer to Figure 62 NOTE A significant amount of transmission fluid may be lost when disconnecting the cooler line fittings Be prepared to catch the fluid in a clean container if reuse is intended It is also important to know how much fluid was lost to re establish fluid level after repair is complete NOTE It is not necessary to drain the transmission fluid for the following procedure However be prepared to lose some fluid all that is above the transmission oil pan splitline about one liter quart 1 Disconnect cooler lines 2 Remove the control main filter by rotating it in the counterclockwise direction using special tool J 45023 54 3 Remove the magnet from the filter attachment tube or from the top of the filter element 4 Clean any metal debris from the magnet Report any metal pieces larger than dust to your service management 5 Remove the 12 bolts fastening the cooler manifold to the converter housing refer to Figure 6 2 6 Remove the cooler manifold separator plate and the gaskets on both sides of the separator plate Be sure that all gasket material is removed from the converter housing mounting face the separator plate and from the cooler manifold 7 Inspect all faces that are adjacent to gaskets prior to installing new gaskets The surfaces must be clean and free of
13. of accumulators and springs which will probably fall from their bores When installing the parts the valve goes in the bore first with the hollow end facing outward followed by the spring which goes inside the hollow portion of the valve 7 To remove Pressure Control Solenoid 1 PCS1 and Pressure Control Solenoid 2 PCS2 remove two bolts and retaining clips holding the reverse signal tube and remove three bolts holding the solenoid retaining bracket To remove Shift Solenoid 3 SS3 or Shift Solenoid 2 SS2 remove the solenoid retaining clip refer to Figure 6 9 NOTE The PCSI PCS2 and TCC solenoid brackets refer to Figure 6 13 must not be modified Note that the angle between the two Figure 6 12 bracket surfaces is less than 90 degrees refer to 69 LESS THAN 90 BY DESIGN 05813 Figure 6 12 PCS1 and PCS2 Retaining Bracket 8 To remove Torque Converter Clutch TCC solenoid remove the retaining bolt and solenoid retaining bracket refer to Figure 6 13 LESS THAN 90 BY DESIGN d V09437 00 01 Figure 6 13 TCC Solenoid Retaining Bracket 70 9 10 Note the position of the solenoid connector and pull the solenoid out of the bore in the control valve body The O rings on the solenoid provide the resistance felt during removal Obtain the new solenoid Lubricate the O rings with clean transmission fluid Push the new solenoid into the control valve body bore
14. of the stall condition If the stall test is repeated do not let the engine overheat 8 Record converter out to cooler temperature 9 Reduce the engine speed to idle and shift the transmission to neutral 10 Raise engine speed to 1200 1500 rpm for 2 minutes to cool transmission fluid 11 At the end of two minutes record converter out to cooler temperature d Driving Transmission Stall Test NOTE If the vehicle is equipped with a smoke controlled or an emission controlled engine or engine control programming inhibiting engine acceleration the following stall test procedure can be used WARNING To help avoid personal injury and or equipment damage a driving transmission stall test must be performed by a trained driver and a qualified technician e Driving Transmission Stall Test Preparation If a driving transmission stall test is to be performed make sure the following preparations have been made before conducting the transmission stall test 1 The manufacturer concurs with performing a full throttle transmission stall test 2 The engine programmable parameter for 0 rpm transmission output speed is set higher than the value expected at transmission stall speed 3 The vehicle is in an area in which the transmission stall test can be safely performed 4 Make sure the fuel control linkage goes to full throttle and does not stick when released 5 Inspect the engine air induction system and exhaust
15. on the main housing 74 2 Place a gasket on the oil pan and align the bolt holes 22 Slide the oil pan gasket and oil pan over the guide bolts and hold them in place while installing two of the bolts to hold the parts in place 23 Install the remainder of the 12 bolts that fasten the oil pan to the main housing two will replace the guide bolts Tighten the bolts to 24 29 Nem 18 21 Ib ft 24 Install the drain plug and sealing washer Tighten the drain plug to 30 40 Nem 22 30 Ib ft 25 Replace the quantity of transmission fluid lost during the solenoid replacement process Refer to MT4007EN for fluid fill and check procedures 6 10 FRONT SEAL REPLACEMENT If front seal leaks are indicated the seal can not be replaced without removing the transmission from the vehicle and the torque converter from the transmission Use the following procedure to replace the front seal that is in the oil pump assembly a Removal CAUTION The torque converter is not bolted to the transmission If the transmission is not maintained horizontally during removal the torque converter may separate from the transmission and cause personal injury and or damage or be damaged 1 Refer to Section in MT4007EN for instructions to remove the transmission from the vehicle During removal be sure to keep the transmission horizontal so that the torque converter stays connected to the transmission and the fluid does not leak out
16. seal using the slide hammer and discard b Installation 1 Inspect the inside diameter of the pump bushing for damage If any portion of the coating reddish color is worn and the steel backing material is visible replace the bushing Refer to Allison Transmission Publication SM3191EN 1000 and 2000 Product Families Service Manual for the correct procedure to remove and install the pump bushing 2 Install a new seal onto the J 43772 installer tool Position the seal so that the rubber enclosed face is against the driving force of the tool refer to Figure 6 15 with the lip of the seal facing toward the pump bushing Place flat steel face of seal against this face TOSS SEAL LIP OUTWARD IPA J 43772 INSTALLER TOOL lt gt V05789 01 00 Figure 6 15 Positioning New Seal on Installer Tool Slide the installer tool over the turbine shaft and ground sleeve until the seal starts into the seal bore Strike the installer tool with a mallet to drive the seal into the seal bore refer to The seal is installed correctly when the shoulder of the installer tool squarely contacts the outer surface of the oil pump B Inspect the converter hub for damage scratches or machine type leading Scratches or machine type leading can cause the seal to leak Remove minor scoring with crocus cloth Lubricate the converter pump hub OD and the front seal with clean transmission fluid TI MALLET
17. system to make sure there are no restrictions 28 f Perform a cold check of the transmission fluid level and adjust as necessary Connect the Allison DOC For Tool to the vehicle diagnostic data connector Install an accurate tachometer do not rely on the vehicle tachometer Install a temperature gauge with the probe in the transmission converter out to cooler line The Allison DOC For PC Service Tool displays sump temperature only Performing A Driving Transmission Stall Test W N ON 8 9 Start the engine While in neutral let the transmission warm to normal operating temperature Sump temperature 71 93 C 160 200 F Converter out temperature 82 104 C 180 220 F Perform a hot check of the transmission fluid level and adjust as necessary Turn OFF all engine accessories While located in an isolated area begin the driving transmission stall test Select a hold range that will limit road speed usually second or third range Never perform a driving stall test in reverse Operate the engine at 100 percent full throttle maximum governed speed With the engine at maximum governed speed begin gradually applying the vehicle service brakes while maintaining 100 percent full throttle CAUTION The transmission stall test procedure causes a rapid rise in transmission fluid temperature that can damage the transmission Never mainta
18. tension or compression on the shift cable Special attention should be devoted to the free pin fit in the N Neutral position in the lowest forward range 1 First and if available in the P Park or PB Auto Apply Parking Brake position refer to Figure 3 6 37 SELECTOR LEVER HELD IN NEUTRAL BY TRANSMISSION DETENT Center cable to midpoint of travel midway between push and pull positions V09464 00 01 Figure 3 4 Proper Shift Selector Cable Adjustment b Replacement Replace the shift selector linkage or cable whenever it does not shift the transmission to the range indicated at the shift selector or when it cannot be adjusted to achieve free pin fit as described in the procedure above Use the following procedure for replacing the shift selector linkage or cable 1 Use process of elimination to find the problem source 2 Disconnect the shift linkage cable at the transmission shift lever end Move the transmission shift lever through each detent position If function is normal the problem must be in the linkage cable or in the shift selector itself If detents cannot be felt or if excessive force is needed to move the lever then the problem may be inside the transmission Proceed to appropriate repair procedure 3 Disconnect the linkage cable from the shift selector at the operator s console If shift selector operation is normal replace the linkage cable If operation is not normal
19. transmission fluid Be sure there are no scratches on the sealing surfaces that could cause a transmission fluid leak b Installation Refer to Figure 6 2 1 Install two headless guide bolts M8 x 1 25 into opposite corners of the cooler manifold mounting face on the converter housing 2 Align the bolt holes in the parts being reinstalled Be sure the parts are in the order shown in 3 Slide the cooler manifold separator plate and the gaskets on both sides of the separator plate over the guide bolts and hold them in place while installing two of the bolts to hold the parts in place 4 Install the remainder of the 12 bolts that fasten the parts to the converter housing two will replace the guide bolts Tighten the bolts to 20 34 Nem 15 25 Ib ft 5 Install the magnet onto the filter attachment tube 6 Lubricate the gasket on the control main filter with transmission fluid 7 Install by hand the control main filter until the gasket on the control main filter touches the converter housing TURN after gasket contact will damage the filter CAUTION Turning the control main filter more than ONE FULL 8 Turn the filter ONE FULL TURN ONLY after gasket contact 9 Connect the cooler lines and tighten the fittings securely 10 Replace the quantity of transmission fluid lost during the gasket replacement process Refer to MT4007EN for fluid fill and check procedures 55 d GASKET SEPARATOR PL
20. vehicle ignition is turned off 2 Disconnect the wiring harness from the speed sensor 3 Remove the bolt from the speed sensor retaining bracket and carefully remove the speed sensor NOTE Do not rotate the sensor in the retaining bracket Orientation is J fixed and if changed may cause improper operation 53 4 Be sure a new O ring is installed on the speed sensor Lubricate the O ring with clean transmission fluid Install the new speed sensor into the speed sensor bore Be sure that the hole in the retaining bracket is aligned with the bolt hole in the speed sensor boss and the speed sensor seats completely in its bore 5 Install the speed sensor retaining bolt and tighten to 10 13 Nem 7 10 Ib ft 6 Connect the wiring harness connector 6 4 PTO COVER GASKET REPLACEMENT Use the following procedure whenever a damaged PTO cover or leaking gasket requires replacement 1 Remove the six bolts which attach the PTO cover to the transmission main housing Remove the PTO cover and gasket Discard the used gasket 2 Be sure the PTO gasket face on the main housing is free of all foreign material nicks and scratches 3 Install the new PTO cover gasket and or cover Start the top center bolt first to hold the cover and gasket in alignment while the other five bolts are installed Install the other five bolts 4 Tighten all bolts to 51 61 Nem 38 45 Ib ft 6 5 COOLER MANIFOLD GASKET REPLACEMENT Some converter
21. with the wiring harness connector in the same position as when the solenoid was removed 20 21 NOTE The PCS2 and TCC solenoids appear to be the same solenoid due to the color of the connector however the TCC solenoid has a smaller snout that consists of two o rings PCS2 only has one o ring Install TCC solenoid retaining bracket Tighten bolt to 10 13 Nem 7 10 Ib ft Install the two accumulators and springs before installing the PCS1 and PCS retaining bracket see NOTE following Step 6 above Install the solenoid retaining clip or bracket Tighten the three bolts which hold the PCS1 and PCS2 retaining bracket to 10 13 Nem 7 10 Ib ft Install the reverse signal tube and retaining clips Tighten the two retaining clip bolts which hold the reverse signal tube to 10 13 Nem 7 10 Ib ft Connect the internal wiring harness to the solenoid Place a new seal on the suction filter tube The seal should locate against shoulder on the suction filter tube Push the filter and seal into the seal bore in the main housing Be sure the suction filter is properly positioned so that the oil pan will clear it and hold it in position Be sure that all gasket material is removed from the main housing and there are no scratches that would cause a splitline leak Install two headless guide bolts M8 x 1 25 into opposite corners of the oil pan mounting face on the main housing Place a gasket on the oil pan an
22. 43911 over the selector shaft with the threaded end toward the seal Be sure that the jackscrew is backed off and will not interfere with installation of the removal tool refer to While pushing the removal tool against the seal rotate the removal tool using a wrench so that the threads on the end of the tool are firmly attached to the steel shell of the seal 5 Apply a wrench to the jackscrew and rotate it clockwise to remove the seal from the bore Discard the old seal 4 2 INSTALLATION Use the following procedure to install the selector shaft seal with the selector shaft in place 1 If not done previously inspect the selector shaft for a shoulder or burr Remove any shoulder or burr with a file 2 Carefully slide a new selector shaft seal over the selector shaft with the wide face of the steel case facing outward refer to Figure 4 2 Position the seal so that it is starting to enter the seal bore 3 Obtain special tool J 43909 and remove the inner sleeve so that the tool will slide over the selector shaft 46 SELECTOR SHAFT SEAL SELECTOR SHAFT K Threaded end toward seal V05800 01 00 Figure 4 1 Selector Shaft Seal Removal 4 Slide the special tool into position so that the end of the tool contacts the seal being installed refer to Figure 4 2 Use a mallet to strike the special tool and drive the new seal into the seal bore until it is seated at the bottom of the bore 5 To m
23. ATE GASKET COOLER MANIFOLD BOLT 8 BOLT CN V05809 01 00 Figure 6 2 Cooler Manifold Gasket Replacement 56 6 6 REAR SEAL REPLACEMENT Use the following procedure to remove and install the output seal located in the rear cover of the transmission a Removal 8 Chock wheels to prevent vehicle movement If present disconnect the parking brake apply linkage cable from the parking brake apply lever Disconnect the vehicle driveline from the transmission output flange yoke Secure the driveline so that it does not interfere with the removal of parking brake components or the output flange yoke Remove the bolt and sealing washer that attaches the output flange yoke to the transmission output shaft Remove the output flange yoke Inspect the seal journal on the output flange yoke Replace the output flange yoke if scratches or machine type leading is present Scratches or machine type leading can cause the seal to leak Replace the output flange yoke if light scoring cannot be removed using crocus cloth Obtain special tool J 24171 A and install the tip with a 90 degree hook onto the end of the slide hammer Position the 90 degree hook behind the rear face of the seal outer case refer to Figure 6 3 Remove the rear seal using the slide hammer b Installation 1 Inspect the seal bore for scratches Inspect the removed seal to determine the cause of a le
24. M J 43772 INSTALLATION TOOL V05790 Figure 6 16 Installing Front Seal 5 Lubricate the converter pump hub OD and the front seal with clean transmission fluid 6 Use the three strand sling to lower the torque converter over the turbine shaft and ground sleeve Remove the three strand sling Spin the torque converter to engage the turbine shaft splines in the torque converter hub the ground sleeve splines in the stator race and the drive flats on the converter pump hub engage the oil pump drive gear 7 The torque converter is correctly installed when the same measurement taken in Step a 3 above is obtained 8 Install the torque converter retaining bracket 9 Install the transmission following instructions in Section V in MT4007EN 6 11 COOLER FLUSHING Metal contamination requires complete transmission disassembly and cleaning Clean all internal and external hydraulic circuits transmission cooler and all areas where metal and other particles could lodge Special tool J 46550 Transmission Cooler Kwik Flush Cart is now an essential tool for all overhaul and maintenance 78 service outlets J 46550 or an approved cooler flushing device that meets Allison cooler flushing requirements and procedures must be used 1 Flush contaminated fluid from the cooler by flowing transmission fluid through the cooler in the reverse direction of normal flow Use a flushing pump that pumps fluid in a pulsating flow at a m
25. Manual SM4006EN Vent dipstick Calibrate dipstick refer to Mechanic s Tips MT4007EN c Table 1 1 Problem NOISE OCCURRING INTERMITTENTLY BUZZING LEAKING FLUID TRANSMISSION OUTPUT Possible Cause Low fluid level Air leak in oil suction screen canister Clogged filter Aerated fluid causes noisy pump Low pressure causes main regulator valve to oscillate Faulty or missing seal at output flange Machine lead on output flange seal surface Troubleshooting Performance Complaints cont d Suggested Remedy Add fluid to proper level refer to Mechanic s Tips MT4007EN Replace suction filter refer to Service Manual SM4006EN Replace filter refer to Section 6 9 Correct fluid level refer to Mechanic s Tips MT4007EN Refer to Low Pressure Section Install new lip type seal in rear of tranmission housing refer to Section 6 6 REAR SEAL REPLACEMENT or Service Manual SM4006EN Replace flange vc Table 1 1 Problem LEAKING FLUID TRANSMISSION OUTPUT cont d LEAKING FLUID TRANSMISSION INPUT Troubleshooting Performance Complaints cont d Possible Cause Rear cover porosity Flange worn at seal surface Insufficient sealant around seal OD Damaged or missing output bolt washer seal Damaged missing or loose flange bolt Front seal leaks Manifold gasket leaks Front support bolt seals leak Converter leaks Suggested Remedy Repair or replace cover
26. OFF position 3 Disconnect the brake apply linkage cable from the parking brake apply lever at the transmission 4 Pull on the parking brake apply lever to remove any slack between the apply lever and the brake shoes Hold the lever in this position and see if the apply linkage cable connection aligns with the hole in the apply lever Adjust the clevis or other adjustment device as required to provide proper alignment 5 Connect the brake apply linkage cable to the parking brake apply lever 6 Do a trial parking brake apply to be sure the adjustment was successful and the parking brake can be completely applied 5 2 REPLACEMENT Use vehicle manufacturer or brake manufacturer instructions whenever possible Use the following general procedure whenever the parking brake must be replaced and no other instructions are available 49 Chock wheels to prevent vehicle movement 2 Disconnect the parking brake apply linkage cable from the parking brake apply lever 3 Disconnect the vehicle driveline from the transmission output flange yoke Secure the driveline so that it does not interfere with the removal of parking brake components 4 Remove the nuts or bolts that attach the parking brake drum to the output flange yoke Remove the brake drum 5 Remove the bolt and sealing washer that attaches the output flange yoke to the transmission output shaft Remove the output flange yoke 6 Remove the four bolts that attach t
27. ak Worn lip Broken garter spring Remove any scratches in the seal bore using crocus cloth Be sure the new seal has blue sealant coating the OD This identifies the seal for use in the 1000 and 2000 Product Families transmissions NOTE The blue sealant identification is important because the 1000 and 2000 Product Families transmissions have an overdrive ratio in fifth range and there is a potential for high output shaft speeds and resultant high seal temperature 57 V SPECIAL TOOL Q 2n J 24171 A Q Zorg Me 8 ee a een Figure 6 3 Rear Seal Removal Install the new seal onto J 43782 units without parking brake provision or J 43783 units with parking brake provision installer tool Position the seal so the seal lip is outward and the face of the steel case is against the driving face of the tool refer to Figure 6 4 4 Slide the installer tool over the output shaft until the seal starts into the seal bore Strike the installer tool with a mallet to drive the seal into the seal bore refer to Figure 6 5 The seal is installed correctly when the shoulder of the installer tool squarely contacts the outer surface of the rear cover CA Lubricate the internal splines and the rear seal journal of the output flange yoke with clean transmission fluid Install the output flange yoke on the transmission output shaft ON Install the bolt and sealing washer that retains
28. ake sure the selector shaft is in the N Neutral position using a wrench on the selector shaft flats carefully rotate the shaft to its furthest clockwise position and then rotate counter clockwise two detents refer to Figure 3 6 4T SELECTOR SHAFT NEW SEAL Started Vs into seal bore V05801 01 00 Figure 4 2 Selector Shaft Seal Installation CAUTION Internal transmission damage will occur if the following instructions are not followed DO NOT drive the selector lever onto the selector shaft DO NOT use an impact wrench to tighten the selector lever retaining nut Hold the lever with a wrench while tightening the nut 6 Carefully slide the selector lever onto the selector shaft and all the way to the shoulder without driving it into place forcing it onto the selector shaft could cause internal damage Using a wrench to keep the selector lever from rotating install the retaining nut and torque it to 20 27 N m 15 20 Ib ft Connect the shift selector linkage cable onto the selector lever refer to Section 3 1 SHIFT SELECTOR AND 48 PARKING BRAKE Section V 5 1 ADJUSTMENT Parking brakes are OEM supplied Follow the vehicle manufacturer or brake manufacturer instructions for adjustment Use the following general procedure if specific information is not readily available 1 Chock wheels to prevent vehicle movement 2 Be sure that the parking brake apply handle or pedal is in the
29. al on the threads Do not reuse retaining bolt Install a new detent lever IMS retaining bolt into the selector shaft Tighten bolt using a T27 bit to 7 0 10 4 Nem 62 92 Ib in Move the control valve assembly into position under the main housing while making sure that the manual selector valve and pin remain in the valve bore and index slot Engage the pin in the manual selector valve into the slot in the detent lever Align the valve body assembly with the dowel pins in the main housing seat the body assembly against the main housing and install one bolt to hold the assembly in place Install the remaining fourteen bolts at locations 1 and 2 refer to Figure 3 8 Tighten the bolts to 10 13 Nem 7 10 Ib ft Attach the IMS connector on the internal harness onto the IMS Push the main electrical connector outward through the hole in the main housing Use tool J 44247 to properly seat the retaining feet to retain the connector in the main housing refer to Figure 3 7 Connect the internal wiring harness Place a new seal on the suction filter tube The seal should locate against a shoulder on the suction filter tube or install a new suction filter with seal attached Push the filter and seal into the seal bore in the main housing Be sure the suction filter is properly positioned so that the oil pan will clear it and hold it in place Be sure that all gasket material is removed from the main housi
30. an overhaul may be required Installation 1 Be sure that all gasket material is removed from the main housing and there are no scratches that would cause a splitline leak Install two headless guide bolts M8 x 1 25 into opposite corners of the oil pan mounting face on the main housing Place the new gasket on the oil pan and align the bolt holes Slide the oil pan gasket and oil pan over the guide bolts and hold them in place while installing two of the bolts to hold the parts in place Install the remainder of the 12 bolts that fasten the oil pan to the main housing two will replace the guide bolts Tighten the bolts to 24 29 Nem 18 21 Ib ft Install the drain plug and sealing washer Tighten the drain plug to 30 40 Nem 22 30 Ib ft SUCTION FILTER AND SEAL SHALLOW PAN SUCTION FILTER AND SEAL DEEP PAN SHALLOW ue 2 SEALING WASHER n SEALING WASHER pA DRAIN PLUG DRAIN PLUG 05810 02 00 Figure 6 6 Oil Pan and Suction Filter 61 7 Replace the quantity of transmission fluid lost during the gasket replacement process Refer to MT4007EN for fluid fill and check procedures 6 8 SUCTION FILTER AND SEAL REPLACEMENT Use the following procedure to remove and install the suction filter and seal Replacement is usually not necessary except at overhaul refer to Figure 6 6 a Removal during the replacement of the suct
31. and there are no scratches that would cause a splitline leak 62 6 9 Install two headless guide bolts M8 x 1 25 into opposite corners of the oil pan mounting face on the main housing Place a gasket on the oil pan and align the bolt holes Slide the oil pan gasket and oil pan over the guide bolts and hold them in place while installing two of the bolts to hold the parts in place Install the remainder of the 12 bolts that fasten the oil pan to the main housing two will replace the guide bolts Tighten the bolts to 24 29 Nem 18 21 Ib ft Install the drain plug and sealing washer Tighten the drain plug to 30 40 Nem 22 30 Ib ft Replace the quantity of transmission fluid lost during the suction filter and seal replacement process Refer to MT4007EN for fluid fill and check procedures CONTROL VALVE COMPONENT REPLACEMENT The control valve components covered as in chassis repairs are the internal wiring harness the pressure switch manifold assembly the solenoids and the internal detent lever assembly These components are typically replaced after a diagnostic process has been completed and a faulty component was identified a Internal Wiring Harness Replacement Use the following procedure to replace the internal wiring harness NOTE It would be helpful to know how much transmission fluid is lost during the replacement of the internal harness Fluid in good condition caught in a clean containe
32. ansmission fluid Push the new solenoid into the control valve body bore with the wiring harness connector in the correct position 11 Connect the internal harness to SS1 Install the solenoid retaining clip 12 Move the control valve assembly into position under the main housing Engage the pin in the manual selector valve into the slot in the detent lever Align the valve body assembly with the dowel pins in the main housing seat the body assembly against the main housing and install one bolt to hold the assembly in place Install the remaining fourteen 1 and 2 bolts refer to Figure 3 8 that fasten the control valve body assembly to the main housing Tighten the bolts to 10 13 Nem 7 10 Ib ft 13 Push the main electrical connector outward through the hole in the main housing Use tool J 44247 to make sure the retaining feet seat the connector in the main housing refer to Figure 6 7 Connect the external wiring harness 14 Place a new seal on the suction filter tube The seal should locate against shoulder on the suction filter tube 15 Push the filter and seal into the seal bore in the main housing Be sure the suction filter is properly positioned so that the oil pan will clear it and hold it in place 16 Be sure that all gasket material is removed from the main housing and there are no scratches that would cause a splitline leak 17 Install two headless guide bolts M8 x 1 25 into opposite corner
33. ce Tool CHECK TRANS light This occurs when the TCM senses a problem but determines the problem won t cause immediate transmission damage or dangerous performance NOTE Diagnostic codes can be logged without illuminating the b Range Inhibit Indicator If the TCM detects conditions such that a shift from neutral to a forward range or to reverse should not be allowed shifts out of neutral may be inhibited At the same time these events occur a required OEM supplied RANGE INHIBIT ED light mounted on the dash or near the shift selector is illuminated This notifies the driver that shifting is inhibited and the shift selector may not respond to shifts requested c Allison Diagnostic Optimized Connection Allison DOC For PC Service Tool Control system diagnostics are performed using a Windows PC operating system and interface software which is available through Allison Transmission tool sources The PC acts as a receiver transmitter display medium that allows the service technician to communicate with the TCM Typical troubleshooting activities performed are installation checkout and diagnostic code retrieval Consult the User Guide which accompanies the Allison DOC For PC Service Tool Figure 1 1 shows a typical beginning screen for the Allison DOC For PC Service Tool The user s manual contains the information for performing the following Displaying retrieving diagnostic trouble codes DTCs transmission diagn
34. ch 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 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 handbook 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 pract
35. circuitry refer to Section 6 3 SPEED SENSOR REPLACEMENT Repair transmission Repair transmission Repair transmission Correct circuit wiring vl Table 1 1 Problem TRANSMISSION WILL NOT STAY IN FORWARD OR REVERSE TRANSMISSION WILL NOT MAKE A SPECIFIC SHIFT Troubleshooting Performance Complaints cont d Possible Cause Auto neutral for PTO circuit input function faulty Low fluid level Leaking at solenoid assembly Low main pressure Faulty solenoid leaking Low engine power Extreme fluid temperature Faulty speed sensor circuit Incorrect engine parameters Faulty temperature sensor circuit Incorrect calibration Faulty or misadjusted shift selector Suggested Remedy Repair quick to neutral circuit Add fluid to correct level Rebuild solenoid assembly refer to Service Manual SM4006EN Refer tc Low Pressure Section Replace solenoid refer to CONTROL VALVE COMPONENT REPLACEMENT Correct engine problem refer to engine Service Manual SM4006EN Inspect cooling system and fluid level Repair circuit or replace speed sensor s Have OEM reset to correct setting Determine if a temperature reading is inhibiting shifts Install proper calibration via PCCS Repair shift selector SI Table 1 1 Problem TRANSMISSION DOES NOT SHIFT PROPERLY ROUGH SHIFTS SHIFTS OCCURRING AT TOO LOW OR TOO HIGH SPEED Troubleshooting Performance Complaints cont d Possible Cause Engine idle sp
36. cleaning solution directly at the breather Spraying steam water or cleaning solution at the breather can force the water or cleaning solution into the transmission and contaminate the transmission fluid 2 If the leak still cannot be identified then clean the suspected area with a degreaser steam or spray solvent Clean and dry the area Operate the vehicle for several miles at varying speeds Inspect the vehicle for leaks If the source of the leak is still not identified use the powder method and or black light and dye method as explained below c Powder Method 1 Clean the suspected area 2 Apply an aerosol type white powder 3 Operate the vehicle under normal operating conditions 4 Visually inspect the suspected area and trace the leak path over the white powder surface to the source NOTE Dye and black light kits are available for finding leaks Refer to J the manufacturer s directions when using the kits Refer to kit directions for the color of the fluid dye mix 33 d Black Light and Dye Method 1 Pour the specified amount of dye into the transmission fill tube 2 Operate the vehicle in normal operating conditions 3 Direct the black light toward the suspected area The dyed fluid will appear as a brightly colored path leading to the source e Repairing the Leak Once the leak has been traced back to its souce inspect the leaking part for the follwing conditions and repair the part Gaske
37. d align the bolt holes Slide the oil pan gasket and oil pan over the guide bolts and hold them in place while installing two of the bolts to hold the parts in place Install the remainder of the 12 bolts that fasten the oil pan to the main housing two will replace the guide bolts Tighten the bolts to 24 29 Nem 18 21 Ib ft Install the drain plug and sealing washer Tighten the drain plug to 30 40 N m 22 30 Ib ft 71 22 Replace the quantity of transmission fluid lost during the solenoid replacement process Refer to MT4007EN for fluid fill and check procedures d Solenoid Replacement SS1 Use the following procedure to replace SSI The control valve body must be completely removed from the transmission NOTE It would be helpful to know how much transmission fluid is lost during the replacement of SS1 Fluid in good condition caught in a clean container may be reused 1 Remove the drain plug and sealing washer from the oil pan and allow the fluid to drain into a suitable container refer to Figure 6 6 Examine the fluid as described in MT4007EN 2 Remove the 12 bolts that fasten the oil pan to the main housing Hold the oil pan in position as the last bolt is removed 3 Remove the oil pan and oil pan gasket Inspect the magnet in the oil pan refer to Figure 6 6 Be sure that excessive or large metallic particles are not present These conditions may indicate that an overhaul is required 4 Remove the
38. d leaks WARNING To help avoid personal injury and equipment damage while conducting a transmission stall test the vehicle must be positively prevented from moving Apply the parking brake the service brake and chock the wheels securely Warn personnel to keep clear of the vehicle and its travel path c Performing a Transmission Stall Test 1 Start the engine While in neutral let the transmission warm to normal operating temperature Sump temperature 71 93 C 160 200 F Converter out temperature 82 104 C 180 220 F 2 Perform a hot check of the transmission fluid level and adjust as necessary 3 Turn OFF all engine accessories 4 Use the Allison DOC For Tool to select fourth range Using fourth range reduces the torque imposed on the transmission driveline Do not perform a transmission stall test in reverse 5 Notify personnel in the area to keep clear of the vehicle 6 Slowly increase engine rpm until engine speed stabilizes 7 Record engine speed 27 CAUTION The transmission stall test procedure causes a rapid rise in transmission fluid temperature that can damage the transmission Never maintain a stall condition once engine speed stabilizes or converter out to cooler temperature exceeds 150 C 300 F During a stall condition converter out temperature rises much faster than the internal sump temperature Never use sump fluid temperature to determine the length
39. e oO eh Rm enm ROS oe Re OR ea Rn 51 5 3 BURNISHING sr Rue a ted ea Rok UR Sr SACK 51 SECTION VI COMPONENT REPLACEMENT 6 1 OUTPUT FLANGE YOKE REPLACEMENT 52 6 2 TACHOGRAPH PLUG REPLACEMENT 52 6 3 SPEED SENSOR REPLACEMENT 33 6 4 COVER GASKET REPLACEMENT 54 6 5 COOLER MANIFOLD GASKET REPLACEMENT 54 6 6 REAR SEAL REPLACEMENT 57 6 7 OIL PAN GASKET REPLACEMENT 59 6 8 SUCTION FILTER AND SEAL REPLACEMENT 62 6 9 CONTROL VALVE COMPONENT REPLACEMENT 63 6 10 FRONT SEAL REPLACEMENT 75 6 11 COOLER FLUSHING eroe dier e e RR RR 78 SECTION VII CUSTOMER SERVICE 7 1 OWNER ASSISTANCE 7 2 SERVICE LITERATURE TRADEMARK USAGE The following trademarks are the property of the companies indicated Allison DOC is a trademark of General Motors Corporation Windows is a registered trademark of Microsoft Corporation Torx is a registered trademark of Camcar Texron WARNINGS CAUTIONS NOTES IT IS YOUR RESPONSIBILITY to be completely familiar with the warnings and cautions described in this handbook It is however important to understand that these warnings and cautions are not exhaustive Allison Transmission could not possibly know evaluate and advise the service trade of all conceivable ways in whi
40. ed position in the U channel Connect the external wiring harness Place a new seal on the suction filter tube The seal should locate against a shoulder on the suction filter tube Push the filter and seal into the seal bore in the main housing Be sure the suction filter is properly positioned Be sure that all gasket material is removed from the main housing and there are no scratches that would cause a splitline leak Install two headless guide bolts M8 x 1 25 into opposite corners of the oil pan mounting face on the main housing Place a new gasket on the oil pan and align the bolt holes Slide the oil pan gasket and oil pan over the guide bolts and hold them in place while installing two of the bolts to hold the parts in place 66 21 Install the remainder of the 12 bolts that fasten the oil pan to the main housing two will replace the guide bolts Tighten the bolts to 24 29 Nem 18 21 Ib ft 22 Install the drain plug and sealing washer Tighten the drain plug to 30 40 Nem 22 30 Ib ft 23 Replace the quantity of transmission fluid lost during the internal harness replacement process Refer to MT4007EN for fluid check procedures b Pressure Switch Manifold Assembly Replacement Use the following procedure to replace the pressure switch manifold assembly NOTE It would be helpful to know how much transmission fluid is lost during the replacement of the pressure switch manifold ass
41. eed too high neutral to range shift Faulty throttle sensor circuit Excessive clutch running clearance Incorrect shift calibration for vehicle Instrument panel tachometer incorrect Incorrectly calibrated electronic speedometer Faulty speed sensor circuit Degraded fluid Loose speed sensor Incorrect fluid level Shift adaptives not converged Suggested Remedy Adjust engine idle speed Refer to Mechanic s Tips MT4007EN and or Troubleshooting Manual TS3977EN Rebuild transmission and adjust clearances Install correct calibration via PCCS Repair or replace tachometer Calibrate electronic speedometer Repair circuit or replace speed sensor s refer to Troubleshooting Manual TS3977EN Change transmission fluid and control main filter refer to Mechanic s Tips MT4007EN Tighten speed sensor retaining bracket bolt Correct fluid level refer to Mechanic s Tips MT4007EN Drive vehicle until shift adaptives are converged 9I Table 1 1 Problem TRANSMISSION DOES NOT SHIFT PROPERLY ROUGH SHIFTS SHIFTS OCCURRING AT TOO LOW OR TOO HIGH SPEED cont d Troubleshooting Performance Complaints cont d Possible Cause Engine parameters not correct Low main pressure Intermittent wiring problems Loose or damaged speed gear Sticking valves in control valve assembly Leaking pressure control solenoids Incorrect TCM calibration Suggested Remedy Have OEM verify engine parameters that ma
42. embly Fluid in good condition caught in a clean container may be reused n 9 Remove the drain plug and sealing washer from the oil pan and allow the fluid to drain into a suitable container refer to Figure 6 6 Examine the fluid as described in MT4007EN Remove the 12 bolts that fasten the oil pan to the main housing Hold the oil pan in position as the last bolt is removed Remove the oil pan and oil pan gasket Inspect the magnet in the oil pan refer to Figure 6 6 Be sure that excessive or large metallic particles are not present These conditions would indicate that an overhaul may be required Remove the suction filter by pulling straight down where the suction tube is seated in the main housing Remove the suction seal from the filter or from the seal bore in the main housing Discard the old seal and the filter if it is being replaced Remove the six bolts that attach the pressure switch manifold assembly to the control valve body Remove the pressure switch manifold assembly from the transmission Inspect the valve body for O ring seals that may have been left from an old pressure switch assembly Remove any old O rings found Place the new pressure switch manifold assembly in position and install NOTE Individual pressure switches cannot be replaced When any pressure switch needs replacing the entire assembly must be replaced one bolt in a recessed location to
43. fer to Mechanic s Tips MT4007EN Rebuild control valve body assembly Refer to Repair or replace pressure control solenoids refer to Service Manual SM4006EN Refer to speed sensor DTCs Overhaul transmission refer to Service Manual SM4006EN RANGE CLUTCH TROUBLESHOOTING SECTION EXCESSIVE SLIPPAGE AND CLUTCH CHATTER Incorrect TCM calibration Throttle Position Sensor TPS out of adjustment or failed Incorrect speed sensor readings Install correct calibration Adjust or replace TPS refer to Mechanic s Tips MT4007EN Refer to speed sensor DTCs 81 Table 1 1 Problem EXCESSIVE SLIPPAGE AND CLUTCH CHATTER cont d A Ranges 1 2 3 4 Only B Ranges 4 5 Only C Ranges 3 5 R Only D Range 2 Only Troubleshooting Performance Complaints cont d Possible Cause Incorrect fluid level Main pressure low TCC clutch not applied C1 clutch slipping leaks at splitline gasket leaks at rotating clutch seals leaks at piston seals C1 clutch plates worn C2 clutch slipping leaks at splitline gasket leaks at rotating clutch seals leaks at piston seals C2 clutch plates worn C3 clutch slipping leaks at piston seals C3 clutch plates worn C4 clutch slipping leaks at piston seals C4 clutch plates worn Suggested Remedy Correct fluid level refer to Mechanic s Tips MT4007EN Refer to Low Main Pressure Section Inspect lockup clutch system wiring pressure and controls repair
44. fluid from a specific vehicle system 2 Operate the vehicle to reach normal operating temperature and park the vehicle Inspect the vehicle to identify the source of the leak b Typical Leak Points and Causes Refer to the following list for possible points of fluid leaks and their causes Transmission mating surfaces Attaching bolts not correctly tightened Improperly installed or damaged gasket Mounting face damaged Housing leak Filler pipe or plug seal damaged or missing Filler pipe bracket dislocated Oil cooler connector fittings loose or damaged Output shaft seal worn out or damaged Pressure port plug loose Porous casting Leak at converter end Converter seal damaged Seal lip cut check converter hub for damage Garter spring missing from seal Converter leak in weld area Porous casting 32 Fluid comes out of fill tube Overfilled incorrect dipstick Plugged breather Water or coolant in fluid fluid will appear milky Drain back holes plugged Visually inspect the suspected area Inspect all the gasket mating surfaces for leaks 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
45. he main housing Discard the old seal and the filter if it is being replaced Disconnect the wiring harness from Main Mod solenoid Remove six bolts retaining the Main Mod solenoid valve body to the control valve body Remove the Main Mod solenoid valve body Turn the Main Mod solenoid valve body hydraulic passages up Remove the solenoid retainer clip Remove Main Mod solenoid from the valve body Lubricate the O rings on the replacement solenoid Install Main Mod solenoid into the valve body electrical connector pointing towards the pressure manifold and parallel to the valve body so that the connector is horizontal when installed in the vehicle Install the solenoid retainer on the hydraulic passage side Install six M6 x 1 5 x 65 mm bolts that retain the modulated main valve body to the main valve body Tighten bolts to 10 13 7 10 Ib ft Connect the internal wiring harness Place a new seal on the suction filter tube The seal should locate against shoulder on the suction filter tube Push the filter and seal into the seal bore in the main housing Be sure the suction filter is properly positioned so that the oil pan will clear it and hold it in place Be sure that all gasket material is removed from the main housing and there are no scratches that would cause a splitline leak Install two headless guide bolts M8 x 1 25 into opposite corners of the oil pan mounting face
46. he parking brake assembly to the rear cover of the transmission Remove the parking brake assembly 7 Install the new parking brake assembly in the same position as the one that was removed Install four bolts which attach the brake assembly to the main housing Tighten the bolts to 90 110 Nem 66 81 Ib ft 8 Lubricate the internal splines and the rear seal journal of the output flange yoke with clean transmission fluid Install the output flange yoke on the transmission output shaft 9 Install the bolt and sealing washer that retains the output flange yoke to the transmission output shaft Tighten the bolt to 110 135 Nem 80 100 Ib ft 10 Install the parking brake drum over the shoes on the parking brake assembly Install the nuts bolts that attach the parking brake drum to the output flange yoke Tighten the bolts to specification 11 Connect the vehicle driveline to the output flange yoke 12 Adjust the parking brake linkage cable refer to Paragraph 5 1 CAUTION Apply the parking brake gradually over 10 15 seconds during burnishing Dynamic braking is not an accepted practice for normal operation Abrupt dynamic apply may cause transmission damage 50 5 3 BURNISHING After installing a new parking brake assembly be sure to follow the burnishing procedure to attain full holding capacity Follow the brake manufacturer s recommended burnishing procedure If a manufacturer s procedure is not available use the fo
47. ice etc if not strictly observed could result in damage to or destruction of equipment NOTE A note is used when an operating procedure practice etc is essential to highlight TROUBLESHOOTING 1 1 GENERAL TROUBLESHOOTING INFORMATION a CHECK TRANS Light The CHECK TRANS light is original equipment manufacturer OEM supplied and usually located on the vehicle s instrument panel The CHECK TRANS light is illuminated briefly during vehicle start up as a bulb check NOTE The CHECK ENGINE light may serve the CHECK TRANS function for vehicles which are compliant to Industry On Board Diagnostics II OBD II requirements When the light is ON shifts may be restricted by the Transmission Control Module TCM when the TCM senses abnormal conditions as follows TRANS light is displayed the transmission may remain in neutral until the code is cleared Leave ignition ON until you are in a safe place to stop 1 WARNING If ignition is turned OFF and then ON while the CHECK The transmission may be locked in the range it was in when the problem was detected The transmission may continue to operate with inhibited shifting The TCM may not respond to shift selector requests Direction changes and shifts from neutral to range may not occur Whenever the CHECK TRANS light is displayed the TCM logs a diagnostic code in memory These diagnostic codes can be accessed through the Allison DOC For PC Servi
48. in a stall condition once engine speed stabilizes or converter out to cooler temperature exceeds 150 C 300 F During a stall condition converter out temperature rises much faster than the internal sump temperature Never use sump fluid temperature to determine the length of the stall condition If the stall test is repeated do not let the engine overheat When the vehicle comes to a complete stop record engine speed Record converter out to cooler temperature 10 Reduce the engine speed to idle and shift the transmission to neutral 11 Raise engine speed to 1200 1500 rpm for two minutes to cool transmission fluid At the end of two minutes record converter out to cooler temperature 29 g Neutral Cool Down Check Procedure 1 At the end of two minutes the converter out to cooler fluid temperature should return to within normal operating temperature range 2 If the transmission fluid does not cool within two minutes the cause could be a stuck torque converter stator or an issue with the transmission cooler lines or fittings h Transmission Stall Test Results NOTE Environmental conditions such as ambient temperature J altitude engine accessory loss variations etc affect the power input to the converter Due to such conditions stall speed can vary from specification by 150 rpm and still be accepted as within published stall speed If engine speed with the transmission stalled is
49. inimum mean rate of 0 5 liters sec 8 0 gpm and 275 345 kPa 40 50 psi The J 46550 Transmission Cooler Kwik Flush Cart meets these requirements 2 After flushing the contaminated fluid use the flushing pump to circulate clean transmission fluid through the cooler in a closed loop back to a 10 micron filter Circulate fluid in the closed loop for a minimum of five minutes circuit for restrictions If circuit pressure drop is above specification the cooler has excessive trapped particles and must be replaced CAUTION After flushing the cooler be sure to test the external cooler 79 Section VII CUSTOMER 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 SA2229EN 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 Fulfil
50. ion filter and seal Fluid in good NOTE It would be helpful to know how much transmission fluid is lost condition caught in a clean container may be reused 1 Remove the drain plug and sealing washer from the oil pan and allow the fluid to drain into a suitable container Examine the fluid as described in MT4007EN 2 Remove the 12 bolts that fasten the oil pan to the main housing Hold the oil pan in position as the last bolt is removed 3 Remove the oil pan and oil pan gasket Inspect the magnet in the oil pan Be sure that excessive or large metallic particles are not present These conditions would indicate that an overhaul may be required 4 Remove the suction filter by pulling straight down where the suction tube is seated in the main housing 5 Remove the suction seal from the filter or from the seal bore in the main housing Discard the old seal and the filter b Installation 1 Place a new seal on the suction filter tube The seal should locate against a shoulder on the suction filter tube CAUTION If a shallow pan and filter were removed reinstall a shallow pan and filter If a deep pan and filter were removed reinstall a deep pan and filter Transmission damage can occur if the correct oil pan and filter are not installed 2 Push the filter and seal into the seal bore in the main housing Be sure the suction filter is properly positioned 3 Be sure that all gasket material is removed from the main housing
51. lectrical connector at the end of the internal harness protrudes through the main housing refer to Figure 3 7 Remove the main electrical connector outer end of internal harness by placing special tool J 47944 over the connector to release the feet that attach the connector to the main housing refer to Figure 3 7 and push inward on the connector Disconnect the internal wiring harness from the detent lever IMS 41 can slide out of the valve bore and index slot in the control valve body assembly Be sure that the manual selector valve and pin do not fall out when removing the control valve body assembly NOTE On some transmission models the manual selector valve and pin 9 Remove fifteen bolts at locations marked 1 and 2 refer to Figure 3 8 Be sure to support the weight of the control valve body about 10 pounds as the last bolt is removed Remove the control valve body assembly from the dowel pins in the main housing When the valve body assembly has cleared the dowel pins move it sideways to disengage the pin in the manual selector valve from the slot in the detent lever Remove the control valve body assembly making sure that the manual selector valve and pin do not fall out during removal V08121 04 00 Figure 3 8 Control Valve Body Removal CAUTION DO NOT mar the main housing surface around the spherical grooved pin when removing the pin An unmarred surface is re
52. lips for SS3 and SS2 which also retain tabs on the wiring harness U channel refer to Figure 6 9 The solenoids will remain in position even after the retaining clips are removed 9 Remove the main electrical connector outer end of internal harness by using special tool J 47944 over the connector to release the feet that attach the connector to the main housing refer to Figure 6 10 and pushing inward on the connector Remove the internal wiring harness from the transmission 10 Place the new internal wiring harness in the approximate position it will occupy after installation 64 CONNECTORS SOLENOID ee LL Figure 6 9 Internal Wiring Harness Removal Installation 11 Push the main electrical connector outward through the hole in the main housing Use special tool J 44247 to make sure the retaining feet seat the connector in the main housing refer to Figure 6 7 65 V09457 00 00 Figure 6 10 Removal Of Main Electrical Connector Align the tabs on the wiring harness U channel with the retaining clip slots for solenoids SS3 and SS2 on the control valve body Install the retaining clips for SS3 and 552 solenoids Figure 6 9 Attach the wiring harness connectors to solenoids refer to Figure 6 9 IMS and to the pressure switch manifold assembly The connectors should be in the correct position for installation because of their pre assembl
53. llison DOC For PC Service Tool d Troubleshooting When No Diagnostic Codes Are Present 1 Always start with the basics Make sure the shifter is in the appropriate range Measure the fluid level Make sure batteries are properly connected and charged Make sure throttle is closed and engine speed is below 900 rpm Make sure electrical connections are properly made nspect and test support equipment for proper installation and operation 2 If adaptive information has been reset initial upshifts and downshift may be harsh Allow shifts to converge before assuming there is a shift problem 3 Refer to Section 1 2 GENERAL TROUBLESHOOTING OF PERFORMANCE COMPLAINTS These troubleshooting charts list a variety of conditions that may or may not relate to the Electronic Control Some conditions and suggested tests include mechanical and hydraulic items 4 If the troubleshooting charts refer to an Electronic Control test use the diagnostic code troubleshooting information that best applies to the situation e Troubleshooting Intermittent Diagnostic Codes Intermittent codes are a result of conditions which are not always present When conditions causing the code exist the code is logged in memory The code stays in memory until it is manually cleared or cycled out When intermittently occurring codes exist determine if any of the following items are at fault Dirty damaged or corroded harness connector
54. llowing procedure which is based on paragraph 7 3 2 of SAE procedure J360 Make ten stops from a maximum speed of 15 kph 9 5 mph using only the parking brake to retard the vehicle Space the stops at least 4 km 2 5 miles apart and operate the vehicle at a minimum speed of 30 kph 18 5 mph between each stop Be sure to readjust the parking brake linkage when the burnishing procedure is completed CAUTION Avoid sustained use of the parking brake while the engine is running and the transmission is in any selector position other than N Neutral P Park or PB Park Brake Apply Failure to observe this practice may cause transmission overheating and premature failure 51 Section VI 6 1 COMPONENT REPLACEMENT OUTPUT FLANGE YOKE REPLACEMENT Use the following procedure whenever an output flange yoke requires replacement due to damage or wear 1 N CA ON oo 6 2 Chock wheels to prevent vehicle movement If present disconnect the parking brake apply linkage cable from the parking brake apply lever Disconnect the vehicle driveline from the transmission output flange yoke Secure the driveline so that it does not interfere with the removal of parking brake components or the output flange yoke If present remove the nuts or bolts that attach the parking brake drum to the output flange yoke Remove the brake drum Remove the bolt and sealing washer that attaches
55. lment Desk 8350 Allison Avenue Indianapolis IN 46268 TOLL FREE 888 666 5799 INTERNATIONAL 317 471 4995 80 Table 7 1 Available Service Literature 81 EA i i GN4008EN 200701 www allisontransmission com Printed in USA 200701
56. more than 150 rpm below the stall speed specification an engine issue is indicated If engine stall speed is more than 150 rpm above specification a transmission issue is indicated Conditions that can exist to cause a stall speed of 150 rpm above specification could be Transmission fluid cavitation or aeration Verify proper fluid level using the oil level sensor if equipped or dipstick Slipping clutch Torque converter malfunction Sticking or damaged torque converter valve A low stall speed at least 33 percent lower than published stall speed could indicate an engine issue or a freewheeling stator in the torque converter 30 1 4 PRESSURE SCHEDULE VERIFICATION Use Table 1 2 to verify proper main pressure Make sure the transmission is at operating temperature when verifying main pressure Table 1 2 Pressure Schedule mma 590 720 kPa 634 758 with Main Mod active 85 105 psi 92 110 psi 700 1380 kPa 1515 1795 kPa Main Mod inactive 101 200 psi 220 260 psi Forward lockup with Main N A 510 627 kPa Mod active 74 91 psi Forward lockup with Main N A 1000 1170 kPa Mod inactive 145 170 psi Mod active 85 105 psi 800 1655 kPa 1515 1795 kPa Mod inactive 130 240 psi 220 260 psi 31 FLUID LEAK DIAGNOSIS 2 1 FINDING THE LEAK a Identify the fluid 1 Determine if the fluid is engine oil automatic transmission fluid or hydraulic
57. ng and there are no scratches that would cause a splitline leak Install two headless guide bolts M8 x 1 25 into opposite corners of the oil pan mounting face on the main housing Place a gasket on the oil pan and align the bolt holes Slide the oil pan gasket and oil pan over the guide bolts and hold them in place while installing two of the bolts to hold the parts in place Install the remainder of the 12 bolts that fasten the oil pan to the main housing two will replace the guide bolts Tighten the bolts to 24 29 Nem 18 21 Ib ft Install the drain plug and sealing washer Tighten the drain plug to 30 40 Nem 22 30 Ib ft 44 27 Replace the quantity of transmission fluid lost during the replacement process Set the transmission fluid level following the procedure in MT4007EN 45 SELECTOR SHAFT SEAL REPLACEMENT 4 1 REMOVAL Use the following procedure whenever the selector shaft seal must be removed with the selector shaft in place 1 Disconnect the shift linkage cable from the selector lever at the transmission 2 To avoid damaging the internal stops while removing the selector lever retaining nut you must keep the selector shaft from rotating against the stops Use a wrench to keep the selector lever from rotating while removing the retaining nut Carefully remove the selector lever from the selector shaft 3 Inspect the selector shaft for burrs Remove burrs with a file 4 Slide special tool J
58. on malfunction Stall testing is a troubleshooting procedure only never perform a stall test as a general test or during routine maintenance Transmission stall speed is the maximum engine rpm attainable when the engine is at full throttle and the torque converter turbine is not moving or stalled After a transmission stall test compare the actual full throttle engine speed at torque converter turbine stall with specifications established by the vehicle manufacturer NOTE Engine speed data can be obtained from the engine manufacturer or from the equipment dealer or distributor Some engine manufacturers provide a programmable parameter to limit engine speed when the transmission output speed is rpm such as at a stop This parameter should be set to a higher value than the expected transmission stall speed before performing the stall test b Stall Testing Preparation If a transmission stall test is to be performed make sure the following preparations have been made before conducting the transmission stall test 1 The manufacturer concurs with performing a full throttle transmission stall test 2 The engine programmable parameter for 0 rpm transmission output speed is set higher than the value expected at transmission stall speed 3 The vehicle is in an area in which a transmission stall test can be safely performed 4 Make sure the fuel control linkage goes to full throttle and does not stick when released 5
59. ostic codes begin with PO P1 P2 UO U1 or U2 followed immediately by three additional numbers For a complete list of codes and more detailed information refer to TS3977EN Electronic Troubleshooting Manual Clearing diagnostic codes Obtaining transmission data such as input speed or sump fluid temperature Conducting solenoid testing Conducting clutch diagnostics including torque converter clutch J Allison DOC TM Trouble Code DJ xj Ele ECU Interface Diagnostic Reprogram Action Request Snapshot Options Help Print Screen Buttons Allison 2 18000480035 2 CONNECTED Transmission F1 Help F2 File F3 Diagnostic F4 Snapshot F5 Connect F6 Fire Trigger F7 Stop Recording Double click a DTC or Description to access the TroubleShooting Manual Double click on the Failure Record field to access its details DTC Active Historic Check Failure Record Description pz v v N Y Transmission Fluid Temperature Sensor Circuit High Input prop v Y xy y Pressure Control Solenoid A Electrical Glear DTC Information Cal ID Software Level Serial Number HCN _ 1 I 180004A003S U2A 860000M301320729 16 Sump Temp PRNDLA PRNDLB PRNDLC PRNDLP Gear Select Attein TCM Input Volts TM 44 off On off NIN 13 4 Connect Time 0 02 00 Figure 1 1 Trouble Code Screen A
60. proper level refer to Mechanic s Tips MT4007EN Replace torque converter Replace torque converter refer to Service Manual SM4006EN Refer to Low Pressure Section Rebuild transmission refer to Service Manual SM4006EN Confirm proper engine match Refer to vehicle engine manufacturer s manual or vehicle service manual Ic Table 1 1 Problem B Low Stall Speeds cont d OVERHEATING IN ALL RANGES Troubleshooting Performance Complaints cont d Possible Cause Stall speeds 33 percent of normal implies freewheeling stator Engine smoke controls Incorrect torque converter Aerated fluid incorrect fluid level Air flow to cooler obstructed Engine overheat Inaccurate temperature gauge or sending unit Inaccurate sump temperature sensor Inadequate cooler sizing Excessive cooler circuit pressure drop Transmission cooler lines reversed Suggested Remedy Replace converter assembly refer to Service Manual SM4006EN Compare lugback vs static stall speed Install correct torque converter refer to Service Manual SM4006EN Adjust fluid to proper level determine if there is a leak in the suction circuit or the pump is defective refer to Mechanic s Tips MT4007EN Remove air flow obstruction Correct overheat situation refer to vehicle service manual Replace gauge and or sending unit Replace Pressure Switch Manifold PSM or internal harness refer to Section 6 9 Refer to vehicle OEM fo
61. quired to maintain the seal between the control valve body assembly and the main housing 42 NOTE The detent lever IMS retaining bolt contains patch lock material on the threads Do not reuse retaining bolt 10 Remove the detent lever IMS retaining bolt using a T27 Torx bit and discard 11 Place a protective plate on the main housing surface around the spherical grooved pin Remove the pin from the main housing 12 Slide the selector shaft through the detent lever IMS assembly and through the selector shaft seal and remove the detent lever IMS assembly 13 Place the new detent lever IMS assembly refer to Figure 3 9 in position in the main housing Install the selector shaft through the selector shaft seal and through the detent lever IMS assembly Push the selector shaft into its final position in the main housing CAUTION DO NOT mar the main housing when installing the spherical grooved pin Use only gentle tapping on the pin Heavy or continued hammering will damage the main housing surface DETENT LEVER TORX RETAINING BOLT V05815 02 00 Figure 3 9 Detent Lever IMS Assembly Replacement 43 14 Install the spherical grooved pin into the main housing that retains the selector shaft Gently tap the spherical grooved pin into the main housing until properly seated 15 16 20 21 22 23 24 25 26 NOTE The detent lever IMS retaining bolt contains patch lock materi
62. r may be reused Remove the drain plug and sealing washer from the oil pan and allow the fluid to drain into a suitable container refer to Figure 6 6 Examine the fluid as described in MT4007EN Remove the 12 bolts that fasten the oil pan to the main housing Hold the oil pan in position as the last bolt is removed Remove the oil pan and oil pan gasket Inspect the magnet in the oil pan refer to Figure 6 6 Be sure that excessive or large metallic particles are not present These conditions would indicate that an overhaul may be required Remove the suction filter by pulling straight down where the suction tube is seated in the main housing Remove the suction seal from the filter or from the seal bore in the main housing Discard the old seal and the filter if it is being replaced 63 6 Disconnect the external wiring harness from the main transmission electrical connector NOTE The transmission main electrical connector is actually one end J of the internal harness which protrudes through the main housing refer to Figure 6 7 MAIN ELECTRICAL CONNECTOR Outer end of internal harness j Sy RETAINING FEET V09457 01 00 Figure 6 7 Transmission Main Electrical Connector 7 Disconnect the internal wiring harness connectors from the solenoids refer to Figure 6 8 Internal Mode Switch IMS and from the pressure switch manifold assembly 8 Remove the retaining c
63. r permit transmission detent to determine actual selector shaft orientation 05806 01 00 Figure 3 1 Proper Shift Selector Cable Adjustment 1 With the engine off set the parking brake and block the wheels to prevent vehicle movement 2 Dettach the cable pivot from the transmission selector lever refer to Figure 3 2 3 Place both the shift selector and the transmission selector shaft in the N Neutral position 35 4 At the transmission end of the cable push the cable to move the shift handle against the end of the shift selector neutral gate Note the position of the pivot at the end of the cable with respect to the hole in the selector lever refer to Figure 3 2 SELECTOR LEVER HELD IN NEUTRAL BY TRANSMISSION DETENT Push cable to move selector handle against end of NEUTRAL gate V09462 00 01 Figure 3 2 Proper Shift Selector Cable Adjustment 5 Pull the cable to move the shift handle against the opposite end of the shift selector neutral gate Note the position of the pivot at the end of the cable with respect to the hole in the selector lever refer to Figure 3 3 6 Center the position of the cable at the midpoint of travel determined by Steps 4 and 5 refer to Figure 3 4 7 Holding the cable at the position determined in Step 6 rotate the pivot on the threaded section of the cable end until it is aligned with the hole in the selector lever refer to Fig
64. r specifications Determine if cooler is plugged lines too small collapsed hoses too many elbows in circuit Connect cooler lines properly oil and water should flow in opposite directions TT Table 1 1 Problem OVERHEATING IN ALL RANGES cont d FLUID COMES OUT OF THE FLUID FILL TUBE AND OR BREATHER Troubleshooting Performance Complaints cont d Possible Cause Transmission cooler lines restricted Torque converter wrong converter no lockup stuck stator or slipping stator Cooler flow loss due to internal transmission leakage Dipstick loose Fluid level too high Fluid level too low Breather stopped up clogged Fluid contaminated with foreign liquid Dipstick or fill tube seal worn Cut C5 piston seal Improperly vented dipstick Incorrect dipstick marking Suggested Remedy Remove restrictions clean or replace lines refer to vehicle service manual Replace converter assembly refer to Service Manual SM4006EN NOTE Stuck stator will not allow cool down in neutral Overhaul transmission refer to Service Manual SM4006EN Tighten cap replace if necessary Drain to proper level refer to Mechanic s Tips MT4007EN Add fluid to proper level Clean or replace breather refer to Service Manual SM4006EN Drain and replace fluid Locate and fix source of additional fluid refer to Mechanic s Tips MT4007EN Replace seals or dipstick Replace C5 piston seal refer to Service
65. s and terminals Terminals not fully seated in connectors Damaged harnesses due to poor routing chafing excessive heat tight bends etc mproperly mounted electronic control components Poor connector seals where applicable allowing moisture to enter Exposed harness wires Electromagnetic Interference EMI generating components and accessories Loose ground connections To help locate intermittents it sometimes helps to place the appropriate tester on the suspect component or circuit and simulate operating conditions wiggle pull bump and bend while watching the tester 1 2 GENERAL TROUBLESHOOTING OF PERFORMANCE COMPLAINTS Make the following general determinations before beginning specific troubleshooting removing the transmission or removing attached components Are wheels chocked Are there active diagnostic codes s the shift selector in N Neutral to allow starting the engine s the battery properly connected and charged s the transmission fluid level correct s voltage to the TCM correct Are engine parameters correct for the transmission s the engine properly tuned s fuel flow to the engine correct s air flow to the cooler and radiator unrestricted 10 Is the driveline properly connected Are there signs of fluid leakage under the vehicle What is the origination point Are hydraulic connections correctly made and not leaking Has vehicle accelera
66. s of the oil pan mounting face on the main housing 18 Place the gasket on the oil pan and align the bolt holes 19 Slide the oil pan gasket and oil pan over the guide bolts and hold them in place while installing two of the bolts to hold the parts in place 20 Install the remainder of the 12 bolts that fasten the oil pan to the main housing two will replace the guide bolts Tighten the bolts to 24 29 Nem 18 21 Ib ft Install the drain plug and sealing washer Tighten the drain plug to 30 40 Nem 22 30 Ib ft 22 Replace the quantity of transmission fluid lost during the solenoid replacement process Refer to MT4007EN for fluid fill and check procedures 2 73 e Solenoid Replacement Main Mod 1 20 Remove the drain plug and sealing washer from the oil pan and allow the fluid to drain into a suitable container refer to Figure 6 6 Examine the fluid as described in MT4007EN Remove the 12 bolts that fasten the oil pan to the main housing Hold the oil pan in position as the last bolt is removed Remove the oil pan and oil pan gasket Inspect the magnet in the oil pan refer to Figure 6 6 Be sure that excessive or large metallic particles are not present These conditions may indicate that an overhaul is required Remove the suction filter by pulling straight down where the suction tube is seated in the main housing Remove the suction seal from the filter or from the seal bore in t
67. suction filter by pulling straight down where the suction tube is seated in the main housing 5 Remove the suction seal from the filter or from the seal bore in the main housing Discard the old seal and the filter if it is being replaced 6 Release the main electrical connector from the main housing as described in Sub paragraph a Steps 6 and 9 of Disconnect internal harness connector from the IMS This allows the internal wiring harness to remain with the control valve body as it is removed NOTE As the control valve body is removed be careful not to lose the manual selector valve pin or allow the manual selector to slide out 7 Remove fifteen bolts at locations marked 1 and 2 refer to Be ready to support the weight of the control valve body about 10 pounds as the last bolt is removed Remove the control valve body assembly from the dowel pins in the main housing When the valve body assembly has cleared the dowel pins move it sideways to disengage the pin in the manual selector valve from the slot in the detent lever Remove the control valve body assembly 8 Remove the wiring harness connector from SS1 Remove the retaining clip for SS1 refer to Figure 6 8 72 9 Note the position of the solenoid connector and pull the solenoid out of the bore in the control valve body The O rings on the solenoid provide the resistance felt during removal 10 Obtain the new solenoid Lubricate the O rings with clean tr
68. the output flange yoke to the transmission output shaft Remove the output flange yoke Lubricate the internal splines and the rear seal journal of the new output flange yoke with clean transmission fluid Install the output flange yoke on the transmission output shaft Install the bolt and sealing washer that retains the output flange yoke to the transmission output shaft Tighten the bolt to 110 135 Nem 80 100 Ib ft If removed install the parking brake drum over the shoes on the parking brake assembly Install the nuts bolts that attach the parking brake drum to the output flange yoke Tighten the bolts to specification Connect the vehicle driveline to the output flange yoke TACHOGRAPH PLUG REPLACEMENT Use the following procedure whenever a tachograph plug is present and requires replacement due to damage or to replace the washer under the plug 52 1 Remove the plug and washer from the rear cover refer to Figure 6 1 Inspect the washer Replace the washer if the joint was leaking or if a new plug is being installed REAR COVER WASHER y PLUG 05808 Figure 6 1 Tachograph Plug Replacement 2 Install the plug and washer into the rear cover and hand tighten Use a torque wrench and tighten the plug to 60 67 Nem 44 49 Ib ft 6 3 SPEED SENSOR REPLACEMENT Use the following procedure whenever the input turbine or output speed sensors require replacement 1 Be sure the
69. the output flange yoke to the transmission output shaft Tighten the bolt to 110 135 Nem 80 100 Ib ft l Connect the vehicle driveline to the output flange yoke 58 STEEL CASE Against this face LIP Facing outward BLUE SEALANT ON O D J 43782 UNITS WITHOUT PARKING BRAKE PROVISION J 43783 UNITS WITH PARKING BRAKE PROVISION Face which contacts rear cover when seal is fully installed V05796 01 01 Figure 6 4 Positioning New Seal on Installer Tool 6 7 OIL PAN GASKET REPLACEMENT Use the following procedure to remove and install the oil pan gasket Replacement is usually necessary to repair a splitline leak a Removal during the replacement of the oil pan gasket Fluid in good condition NOTE It would be helpful to know how much transmission fluid is lost caught in a clean container may be reused 1 Remove the drain plug and sealing washer from the oil pan and allow the fluid to drain into a suitable container refer to Figure 6 6 Refer to MT4007EN for fluid fill and check procedures 2 Remove the 12 bolts that fasten the oil pan to the main housing Hold the oil pan in position as the last bolt is removed 59 VO5797 01 00 3 Figure 6 5 Installing Rear Seal Remove the oil pan and oil pan gasket Inspect the magnet in the oil pan Be sure that excessive or large metallic particles are not present These conditions would indicate that
70. tion from a stop changed Are electrical connections correctly made Are there any other obvious vehicle or transmission problems After making these general determinations use the various sections of this manual to isolate the listed problems Table 1 1 addresses specific vehicle complaints Some complaints involve diagnostic codes so all troubleshooting should involve determining if diagnostic codes have set 11 1 1 Problem VEHICLE WILL NOT START ENGINE WILL NOT CRANK CHECK TRANS LIGHT WILL NOT GO OUT AT START UP CHECK TRANS LIGHT FLASHES INTERMITTENTLY Possible Cause Lever shift selector not in N Neutral P Park or PB Auto Apply Parking Brake Dead battery Disconnected battery Faulty starter circuit Faulty Internal Mode Switch IMS Faulty wiring in vehicle neutral start circuit or relay Electrical connector not properly seated on IMS TCM has logged a DTC Faulty CHECK TRANS light relay or circuit Intermittent power to TCM Faulty vehicle wiring Loose wiring to CHECK TRANS light Faulty or incorrect ground wire attachment Intermittent opening in Circuit 129 Troubleshooting Performance Complaints Suggested Remedy Select N Neutral and restart Recharge battery Reconnect battery Repair vehicle starter circuit Replace IMS refer to Section 3 2 INTERNAL MODE SWITCH IMS Repair wiring Properly install electrical connector Install Allison DOC
71. ts Fluid level pressure is too high Plugged breather or drain back holes Improperly tightened fasteners or dirty damaged threads Warped flanges or sealing surfaces Scratches burrs or other damage to a sealing surface Damaged or worn out gasket Seals Fluid level pressure is too high Plugged breather or drain back holes Damaged seal bore Damaged or worn out seal Improper installation Cracks in component Output yoke surface scratched nicked or damaged Loose or worn out bearing causing excess seal wear Sealing Flange Inspect the sealing flange for bends replace the part with the damaged flange 34 SHIFT SELECTOR CABLE LINKAGE 3 1 SHIFT SELECTOR AND CABLE LINKAGE a Adjustment The transmission internal detent lever and spring must dictate the position of the manual selector valve in the control valve body Any customer furnished shift selector system must be designed and adjusted to accomplish this positioning The shift selector must move the internal detent lever from position to position and not interfere with the ability of the internal detent spring to position the manual selector valve When the internal detent spring is in the center of a detent lever position the shift selector handle should be in the center of the shift selector gate refer to Figure 3 1 Follow the procedure below to adjust the shift selector cable at the shift lever on the transmission Gates in shift selecto
72. ure 3 5 8 Verify that the attachment pin of the pivot does not bind in the selector lever hole and that the detent in the transmission is positively engaged This condition is sometimes called free pin fit referring to lack of friction at the cable shift lever interface once the transmission detent is engaged Repeat Steps 4 through 6 as necessary to create this condition 36 SELECTOR LEVER HELD IN NEUTRAL BY TRANSMISSION DETENT Pull cable to move selector handle against opposite end of NEUTRAL gate V09463 00 01 Figure 3 3 Proper Shift Selector Cable Adjustment 9 Attach the pivot to the selector lever and secure with the lock pin If a jam nut is provided with the cable hardware tighten the jam nut to lock the pivot to the cable end as noted in Figure 3 5 If the cable manufacturer does not provide a jam nut with the cable assembly do not add one during the installation process NOTE Once the jam nut is tightened the pivot pin should slide freely into the hole in the lever Do not twist the cable to insert it into the lever Loosen the jam nut re orient the pivot to insert freely into the lever then tighten the jam nut again 10 Once this attachment is made move the selector through all the range positions at the operator s station Verify that free pin fit exists in each range position and that the position of the shift lever is determined by the internal transmission detent not by
73. y affect transmission performance Refer tc Low Pressure Section Inspect wiring harnesses and connectors refer to Troubleshooting Manual TS3977EN Tighten output flange bolt or replace speed gear Overhaul control valve body assembly Repair or replace pressure control solenoids refer to CONTROL VALVE COMPONENT REPLACEMENT Install correct calibration via PCCS ABNORMAL TRANSMISSION ACTIVITIES OR RESPONSES A Excessive Creep in First and Reverse Gears B Vehicle Moves Forward in Neutral C Vehicle Moves Backward in Neutral Engine idle speed too high C1 clutch failed or not released C3 clutch failed or not released Adjust engine idle speed Rebuild C1 clutch assembly refer to Service Manual SM4006EN Rebuild C3 clutch assembly refer to Service Manual SM4006EN LI Table 1 1 Problem EXCESSIVE FLARE ENGINE OVERSPEED ON FULL THROTTLE UPSHIFTS Troubleshooting Performance Complaints cont d Possible Cause TPS Adjustment Overstroke Loose Incorrect calibration Incorrect fluid level Sticking valves in control valve assembly Low main pressure Leaking pressure control solenoids Erratic speed sensor signal Piston seals leaking or clutch plates slipping in range involved Suggested Remedy Adjust TPS linkage for proper stroke refer to Mechanic s Tips MT4007EN Tighten loose bolts or connections Install correct calibration via PCCS Add fluid to proper level re

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