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Mechanic`s Tips 3000 And 4000 Product Families

1. 14 6 104100 H3A00 uv3H NJ ul TINGON 27 2 310000 HOLNTD 59 am df1901 HO1f119 92 H LNTO v2 301915 HaldVQV 92 H LNTO 59 18044106 11084 ONISNOH NIYIN 10 99 FINGOW ONISNOH NIVIN TINGON LNOHJ JINGOW 1 Figure 1 5 4000 Product Family Transmission 7 Speed Cross Section 12 ASSEMBLY PADS PTO PROVISION INPUT SPEED pos SENSOR SENSOR FEEDTHROUGH HARNESS CONNECTOR A 2 K COOLER PORTS NOTE Inch Series Threads io NAMEPLATE MAIN PRESSURE NOTE Inch Series Threads RIGHT REAR VIEW BREATHER FEEDTHROUGH HARNESS 2 CONNECTOR TORGUE CONVERTER Nx S WITH LOCKUP CLUTCH 2 S ASSEMBLY PADS AND TORSION
2. REAR WITHOUT RETARDER FRONT ACCUMULATOR LINE SPEED AND LINES nS SENSOR F NECESSARY RETARDER 2 TACHOGRAPH amp WZ TEMPERATURE 22 SENSOR RETARDER FEEDTHROUGH HARNESS CONNECTOR 1 846 7 PLLA NA 7 TURBINE SPEED 72 SENSOR ENGINE SPEED SENSOR REAR COOLER REMOTE COOLER PORTS MANIFOLD RIGHT SIDE REAR WITH RETARDER V07315 Figure 3 1 4000 Product Family Transmissions Disconnect Locations 3 4 REMOVING THE TRANSMISSION 1 Move the transmission away from the engine approximately 110 mm 4 35 inches until it is completely clear of the engine If used remove the adapter ring and or gasket 2 Raise or lower the transmission as necessary to remove it from the vehicle 3 5 REMOVING OUTPUT FLANGE OR YOKE If replacing the transmission you may need to transfer the output flange or yoke to the replacement transmission Before December 1 1998 output flanges or yokes were retained by two M10 x 1 5 x 30 bolts Output flanges or yokes are now retained by one M14 x 2 0 x 70 bolt For the 3000 Product Family the one bolt design began at S N 6510184819 For the 4000 Product Family the one bolt design began at S N 6610038064 All 4000 Product Family use the
3. Figure 2 1 Typical Shift Selectors Information is displayed immediately if the two minute time period elapsed before a fluid level data request was made However if the two minute period has not elapsed there will be a countdown display before fluid level information displays The countdown display flashes constantly Countdown starts at 8 and decreases sequentially to 1 during the two minute period When fluid level data is requested and the two minute countdown is in process the flashing display shows the number corresponding to the countdown progress For example If the fluid level data was requested in the middle of the two minute countdown period the display would flash a 5 or a 4 and decrease to 1 Shift Selector Display Fluid level information is displayed one character at a time as in Table 2 1 22 Table 2 1 Fluid Level Shift Selector Display Display Seguence Interpretation of Display oL oK Fluid level is correct oL Lo 1 Fluid level is 1 quart low oL HI 1 Fluid level is 1 quart high The shift selector display will also show invalid for display codes one character at a time An invalid for display code is returned when fluid level data is requested but an operational condition has not been met The invalid for display condition interrupts the two minute countdown momentary increase in engine speed does not affect the countdown The invalid for display codes and t
4. ap s no ejejdxejj 645 101590 ul 671 V m 416670 56 2 ut Sp gg e gt 16080 0068 4 9 18 06 pz 18 807 95 98 Figure 5 2 4000 Product Family Engine Adaptation 61 h Flexplate Bolt Flatness Flexplate flatness in the area of the bolt holes is not a measurement reguired for the 3000 and 4000 Product Families transmissions 1 Torgue Converter Axial Location Using a depth gauge measure from the face of the torgue converter housing to the torgue converter flexplate adapter mounting face The torque converter axial location should measure 3000 Product Family 49 36 50 38 mm 1 943 1 983 inches 4000 Product Family 45 54 mm 1 793 inches V01717 Figure 5 3 Converter Axial Location Measurement 5 2 CHECKING FLEXPLATE DRIVE ASSEMBLY a Flexplate Inspection Inspect the flexplate for cracks distortion or elongated bolt holes Replace a worn or damaged flexplate b Engine Crankshaft End Play Be sure engine crankshaft end play is within the engine manufacturer s specifications NOTE When assembling the flexplate to the crankshaft hub or hub adapter be sure the outer flexplate bolt holes are aligned HUB ADAPTER STARTER RING GEAR WEAR PL
5. cere 926 e a NIN 0 gt s ualdvav ANH 14 NO 600 80 91 SNIQV3H HOLVOJONI 17101 WAWIXYN 10114 NIW 290 0 0911 410010 syuawasinbad 10 191 i 8 ynsuod 1108 14 5 amp gt H h LAYHSYNYYO uonisod 104 MIIA 995 1N3A Aeme NI 151070 geo Buraq 1 1 isi ap s no ejejdxoj 866 1 97 05 19155 95 62 69 0 anbioy ualdvav 1 14 314 uy 86 0 0768 x sz Lx HOLVOJONI 7 101 5000 epo 1108 01 SS320V 14 55322 841 75 90 u N 2 9 0 800401 10 MIIA 225 qi 88 86 19 18 0 x 00 910 ul 16100 us Wo 041 62 60 68 66 0 0 Bulag 8670 PISO res x sz LX 80 21 Jejouieip ap s no eje dxojj 1108
6. All features of the transmission and the vehicle involved in installation procedures are discussed The information presented will help the mechanic maintain remove or install the transmission in a manner that promotes satisfactory operation and long service life For additional detailed information refer to the appropriate transmission service manual and electronic controls troubleshooting manual Unless specifically indicated otherwise this handbook refers to all 3000 and 4000 Product Families on highway transmissions except 7 speed models The differences between the various transmissions are explained as required 00 80 08 14 5 SNISYNL HOLNTD 29 HOLNTD 19 HOLNTD ONILVLOH uv39 Old 5 H31H83ANOO S IOHLNOO JINON ONISNOH H31H3ANOO OrinvadAH 08193713 JINON 1081409 YOSNAS 13431 110 JINdON 14 JINdON 14VHS JINGOW 43409 15 NNS d 1 19 NNS amoo1 14 TINGON 13 NIV JINGON 1 H LNTI 89 HOLNT9 9 89 did 10 ONISNOH NIYIN 18044005 INOHJ JINGON ONISNOH NIV JINGOW 110 L4OddnS LNOHJ ission Figure 1 1 3000 Product Family Transm with PTO Cross Section 14 5 INISHNL 22 12 3100
7. pue 1 5 QOZ 0008 serur 0006 5 MALTA uzu oqu T 9qn T sS NOLLVOOA NOLLVOOA 0007 404 sjeA191u 1eyrj pinj4 79 2 30 SI 11090 posde o 10 sujuour 8 popuoururooo1 20 Je 1500 SIO sisA eue asn oy pezrumdo oq speA1ojur pue uorssrusuvi UOISSTUISULIJ JO s eA1ojur 8 WY seau juonbayy 10 o oKo 10 Jo 2207 1 tad 03 ouo enbo 10 552 12 gt 194 dos ouo uey 8 YM pue 315481 HUOLIA BAI x 0005 smoH 0005 smoH 000 smoH 0002 smoH 0002 smoH 0007 SLOW SLOW SUON SUON SUON 000 08 000 08 000 OFZ 00
8. 9c 000 021 000 021 000 000 021 000 021 000 STN 000 SL sem 000 6 SAN 000 091 SON 000 Sofia 000 6 SIAN 000 SL 562 SAL m PUA URIL speA19jup ILA pue POPOPSET N d soumbos 4pojeunxoadde your lt lt IMPON 1043407 Your p ping posn jo 001 jo 3uLnsse soruejsrsuoour pue JOU sourgoeur 815114 891198 UO1SSTUISULIJ uosi V JO osn ATUO pue IMPAS UT 8 4 0007 pesn 5 1 uosi V 8 ping SAL 10 juoo1ed 001 Sururejuoo uorssrursuei uodn c pue suonepuoeuruiooo1 eur ALON 0001 smoH 0001 SINOH 0001 SINOH 006 SINOH 006 SINOH 005 suon suon suon 9 9 9 000 000 OF 000 0f 000 02 000 02 000 00 S N 000 5 meyra SN 0009 SOMN 00050 SON 00001 meyrao SIN 00001 SIN 00021 S67 S3LL UoN j Pu SueA uoN
9. e This occurs when the ECU senses abnormal conditions in the transmission e During this time the digit on the shift selector displays the range in which the transmission is locked e The transmission may continue to operate with inhibited shifts The ECU will not respond to shift selector requests Direction changes and shifts to and from neutral will not occur If the ignition is turned OFF and then ON while the CHECK TRANS light is illuminated the transmission will remain in neutral until the diagnostic code is cleared 40 Whenever CHECK TRANS light is illuminated the ECU logs a diagnostic code in memory The diagnostic codes can be accessed through the shift selector display or through the Allison DOC service tool CHECK TRANS light This occurs when the ECU senses a problem but determines that the problem will not cause immediate transmission damage or dangerous performance NOTE Diagnostic codes be logged without illuminating the b Diagnostic Codes Diagnostic codes are stored in memory Up to five codes in memory positions 41 through 45 can be stored with the most recently stored code displayed first Table 2 10 Diagnostic Codes Overview Ignition Code List Main Active Cycle Position Code Subcode Indicator Counter 21 12 21 12 Displayed on shift selector and Allison DOC service tool YES mode indicator LED illuminated Accessible by
10. All son Iransmuission Mechanic s Tips 3000 and 4000 Product Families MT3004EN 2006 MARCH ps MT3004EN Allison Transmission Allison WTEC Controls Except 3000 Product Family 7 Speed 3000 Product Family 4000 Product Family 2 Allison Transmission Allison Transmission Gen rs Corporation Box 894 n dia napolis In 46206 0894 www allisontransmission com Printed in USA Copyright 2006 General Motors Corporation 5 TABLE 5 SECTION INTRODUCTION 1 1 ABOUT THIS MANUAL SECTION PREVENTIVE MAINTENANCE 2 1 PERIODIC INSPECTION AND CARE 2 2 IMPORTANCE OF PROPER TRANSMISSION FLUID LEVEL 2 3 TRANSMISSION FLUID TEST 2 4 KEEPING PLUID CLEAN ieceri bts 2 5 FLUID RECOMMENDATIONS 2 6 TRANSMISSION FLUID AND FILTER CHANGE INTERVALS 2 7 TRANSMISSION FLUID CONTAMINATION 2 8 TRANSMISSION FLUID AND FILTER CHANGE PROCEDURE 2 9 FLUID LEAK DIAGNOSIS 2 10 BREATHER 55 pe Rte IR SEU Rn 2 1 TROUBLESHOOTING 2 12 TRANSMISSION STALL TEST AND NEUTRAL COOL DOWN CHECK Qoid ERE E xs SECTION REMOVING TRANSMISSION 3 1 DRAINING TRANSMISSION 3 2 DISCONNECTING CONTROLS
11. WARNING To help avoid personal injury or property damage caused by sudden and unexpected vehicle movement do not determine the fluid level until you 1 Put the transmission into N Neutral 2 Apply the parking brake and emergency brakes and make sure they are properly engaged 3 Chock the wheels and take any other steps necessary to keep the vehicle from moving Clean all dirt from around the end of the fluid fill tube before removing the dipstick Do not allow dirt or foreign matter to enter the transmission Dirt or foreign matter in the hydraulic system may cause undue wear of transmission parts make valves stick and clog passages Determine the fluid level using the following procedure and report any abnormal fluid levels to your service management c Cold Test Procedure The purpose of the cold test is to determine if the transmission has enough fluid to be safely operated until a hot test can be made CAUTION The fluid level rises as fluid temperature increases DO NOT fill above the COLD CHECK band if the transmission fluid is below normal operating temperature During operation an over full transmission can become overheated leading to transmission damage 1 Park the vehicle on a level surface Apply the parking brake and chock the wheels 2 Run the engine for at least one minute Shift to D Drive then to N Neutral and then to R Reverse to fill the hydraulic system 3 Shift to Neutra
12. 3011 2 H LNT 69 ONISNOH NIVIN JINdOW ONISNOH NIVIN 3NISUNL JINdOW 1 dINNd 10 190 5 LNOYS JINGON 110 1804405 LNOYS ission Figure 1 3 4000 Product Family Transm with Retarder Cross Section 10 00 00882 0A ldVHS ANISYNL H LNTO 29 HOLATS 9 JINON HO1fTO ONILVLOH uv39 Old SNISNOH H3183ANO2 JINON ONISNOH H31H3ANOO 81081 03 0819313 JINGON 1081 Ld JINGOW 1514 52 JINdON 5 LAdLNO JINGON Y43409 NNS NNS 1JVAS NIYIN JINdON 14 5 NIVIN Y3dWYO HOLNTO 3NISUNL S9 JINON H3183ANO9 79 1 19 69 did 110 ONISNOH NIVIN 14044105 LNOYS JINON ONISNOH NIVIA JINGOW 110 14OddnS LNOHJ ission Figure 1 4 4000 Product Family Transm with PTO Cross Section 11 H LNTO 29 H LNTO 19 1 JINdoWn H LNTO ONILVLOH ONISNOH H31H83ANOO JINGOW ONISNOH 00 0 19950 H3IL4IANO9 ool le 14 1 B 31000N TINON d _ NIVM JINON 5 NIVIN
13. HOT FULL and the NOTE Safe operating level is within the HOT RUN band on the HOT ADD bands Refer to Figure 2 2 e If the fluid level is not between the HOT FULL and HOT ADD bands refer to Figure 2 2 add or drain fluid as necessary to bring the fluid level within these bands e Consistency of Readings Always determine the fluid level at least twice with the engine running Consistency repeatable readings is important to maintaining accuracy of the readings If inconsistent readings persist inspect the transmission breather to be sure it is clean and unclogged 25 3000 PRODUCT FAMILY 4000 PRODUCT FAMILY gt 6 35 mm 0 250 in REFERENCE lt Blade can be as narrow as 4 76 0 187 F nu i m TUBE Y 1 EE 84 qo a qo Ha JH Y Tl S TRANSMISSION CONTROL MODULE TRANSMISSION SUMP en 2 00 106 7 76 2 66 0 132 6 13 8 4 00 4000 PRODUCT FAMILY 4200 300in 2 60 in 52210 0 54 in 101 6 73 7 50 8 mm 86 6 5 9 2 00 in 3000 PRODUCT FAMILY 4 00 in 290in 2 00 in 3 41 in 0 23 in 101 6 mm 63 5 mm 45 7 mm 86 6 mm 5 9mm NOTE Calibrate level marking locations with respect to transmission control module split li
14. If the level is too high the fluid aerates causing the transmission to shift erratically and overheat Fluid may be expelled through the breather or dipstick tube when the fluid level is too high 2 3 TRANSMISSION FLUID TEST a Electronic Fluid Test Procedure Fluid level can be electronically displayed on a pushbutton non strip type shift selector lever shift selector or Allison DOC For PC Service Tool if there is an oil level sensor OLS installed and autodetected by the WTEC III control system Frequently test for the presence of oil level diagnostics if the transmission is known to contain an OLS If an OLS is not detected during the first 49 engine starts the WTEC III system concludes that no OLS is present If an OLS is known to be present but has not been autodetected then troubleshoot the OLS circuit After the OLS circuit is repaired reset autodetect or manually select the OLS function using the Allison DOC service tool and then reset autodetect refer to TS2973EN WTEC III Troubleshooting Manual for detailed troubleshooting procedures e Displaying Fluid Level Information Use the following procedure to display fluid level information refer to Figure 2 1 For a pushbutton shift selector Simultaneously press the Down arrow buttons once For a lever shift selector Press the DISPLAY MODE DIAGNOSTIC button once For Allison DOC For PC service tool Connect
15. PTO BOTTOM LEFT V POSITION US TT lt COOLER PORTS MAIN PRESSURE TAP REAR VIEW LEFT V07291 00 01 Figure 1 10 4000 Product Family Transmission with PTO RETARDER RIGHT POSITION MOUNTING PADS FEEDTHROUGH HARNE BOTH SIDES CONNECTOR RIGHT FRONT VIEW MOUNTING PADS BOTH SIDES FEEDTHROUGH HARNESS CONNECTOR RETARDER 71738 SUMP BOTTOM LEFT 4G V PROVISION POSITION MAIN PRESSURE TAP LEFT REAR VIEW V07292 03 00 Figure 1 11 4000 Product Family Transmission with Retarder and PTO 18 MOUNTING PADS BOTH SIDES RIGHT POSITION FEEDTHROUGH HARNESS CONNECTOR C6 ADAPTER HOUSING REAR COVER PTO BOTTOM LEFT POSITION MAIN PRESSURE TAP LEFT REAR MOUNTING PADS BOTH SIDES RIGHT POSITION C6 ADAPTER HOUSING RETARDER PTO BOTTOM LEFT POSITION MAIN PRESSURE TAP PORTS LEFT REAR V07399 00 02 Figure 1 12 4000 Product Family 7 Speed Transmission with PTO Top and 7 Speed with PTO and Retarder Bottom 19 PREVENTIVE MAINTENANCE 2 1 PERIODIC INSPECTION AND CARE Clean and inspect the exterior of the transmission at regular intervals Severity of service and operating conditions determine the frequency of these inspections Inspect the transmission for Loose bolts trans
16. Strip Pushbutton Shift Selectors cannot display or clear After road testing the vehicle determine if any diagnostic codes have set Retrieve the codes by using the shift selector Refer to Figure 2 4 e Enter diagnostic mode The display will list the first code s logged position 41 then follow with the main code and a subcode refer to Table 2 11 for display sequence This display seguence repeats until the MODE button is pressed again Momentarily press the MODE button to move to the next code stored in memory When the MODE button is pressed after displaying the code in the d5 position the code in the 41 position is displayed Any code position that does not have a code set will display a dash as well as all subseguent positions thereafter NOTE You can also use the Allison DOC For PC Service Tool to clear and retrieve the troubleshooting codes Refer to Allison DOC For PC Service Tool 5 Manual GN3433EN for specific instructions e Troubleshooting When No Diagnostic Codes Are Present e Always start with the basics Make sure the shifter is in the appropriate range Inspect the fluid level Make sure batteries are properly connected and charged Make sure electrical connections are properly made Inspect support equipment for proper installation and operation e If the troubleshooting charts refer you to an Electronic Control test procedure use the diagnostic code tr
17. TranSynd or DEXRONC III Correct fluid level in transmission Dipstick correctly calibrated refer to Figure 2 2 Hill tube tight Hill tube cap tight Breather clean and free of restrictions No fluid leaks during operation Instruments and Electrical Equipment for Proper wiring and electrical connections Instruments gauges and lights work correctly Shift Selector display is on and CHECK TRANS light is off Fluid temperature gauge Power Takeoff if installed for Controls connected and operative Correctly coupled to driven equipment Lubrication line correctly installed and routed if used 77 7 2 ROAD TEST AND VEHICLE OPERATION INSPECTION LIST a Driveability NOTE Refer to the latest edition of the 3000 and 4000 Product Families Transmission 5 Handbook or 3000 and 4000 Owner s Manual for operating instructions Refer to the Customer Service section Table 8 1 for the latest publication number Drive away tests are performed to verify proper transmission and support equipment installation and operation The following steps outline drive away test procedures Determine fluid level fill the transmission with the appropriate fluid e Start the vehicle determine proper system response during start up Turn on the vehicle s master ignition switch The CHECK TRANS light should come on Start the engine The CHECK TRANS li
18. b Flywheel Housing Pilot Bore Diameter The flywheel housing pilot bore diameter must measure 3000 Product Family 447 68 447 81 mm 17 625 17 630 inches 4000 Product Family 511 18 511 30 mm 20 125 20 130 inches c Flywheel Housing Bore Runout Flywheel housing bore runout cannot exceed 0 51 mm 0 020 inch TIR d Flywheel Housing Face Squareness The flywheel housing face cannot be out of square more than 0 51 mm 0 020 inch TIR e Crankshaft Hub Pilot or Adapter Diameter The crankshaft hub pilot or hub adapter pilot diameter must measure between 50 94 50 99 mm 2 006 2 008 inches f Crankshaft Hub Pilot or Adapter Squareness The crankshaft hub or hub adapter cannot be out of square more than 0 13 mm 0 005 inch TIR g Crankshaft Hub Pilot or Adapter Concentricity The crankshaft hub pilot or the hub adapter pilot concentricity cannot exceed 0 13 mm 0 005 inch TIR 59 80 00 96860 SLNAWSAYINOAY NOILVIdVQV 3NION3 WIV1O 39VdS H3lH3ANOO NOISSINSNVHL 43ldvaV 1 NO HOLVOIGNI 1 101 60070 21 0 13 LIVHSYNVYO 3NI9N3 418002 14 90072 NO 1 66 09 96 05 VIG 17101 WAWIXVW 5000 70 gt
19. 51 YOU 10 c 965 lt IMPAS ping jo 001 jo SULINSS YILMA pue JOU series p or uosi y JO esn ATUO AMPAS ur s eA1ojur 000 PING S67 SAL 10 y PUK URIJ 4 001 Sururejuoo uorssrussue uodn poseq 0001 smoH 0001 SINOH 0001 SINOH 006 SINOH 006 SINOH 005 suon 5 cT spuon 9 SUON 9 9 000 000 OF 000 OF 000 00 000 02 000 00 SOMN 000 1184790 SON 000 CZ SOMN 00050 SPINAL 000 000 SON 000 0 10 S67 SAL UON n PU ULAL UON IMPAS 005 WJ 0008 SAT 0005 TVAWALENI WALA IVELINI euu 9 9quT NOLLV9JOA NOLLVOOA 0006 10 1ejJ pini4 76 2 91461 SINOH 0006 SINOH 0006 SINOH 0007 SINOH 0006 SINOH 0006 SINOH 0006 SUON 9c SUON 9c SUON 8p 9c 96
20. Allison DOC service tool Diagnostic codes consist of a two digit main code and a two digit subcode refer to Table 2 10 Main codes are listed first and provide the general condition or area of a fault detected by the ECU e Subcodes are listed second and provide specific areas or conditions within the main code that caused the fault e Example of Code 13 12 13 indicates a problem with ECU voltage 12 indicates the problem is caused by low voltage e Example of Code 32 12 32 indicates a problem with the throttle position sensor signal 12 indicates that the throttle position sensor signal is low Diagnostic codes are displayed one character or digit at a time Table 2 11 is example of code 21 12 Each character or digit is displayed for about one second 41 Table 2 11 Diagnostic Code Display Code List Position ke 2 1 1 A When using the shift selector to retrieve trouble codes if the mode indicator LED is illuminated the displayed code is active If the mode indicator is not illuminated the displayed code is inactive In normal operating mode an illuminated mode indicator signifies secondary mode operation e The Ignition Cycle Counter determines when inactive diagnostic codes are automatically cleared from the code list The counter is incremented each time a normal ECU powerdown occurs ignition turned off Inactive codes are cleared from the code list after the Ignition Cy
21. Apply an aerosol type white powder to the suspected area 3 Operate the vehicle under normal operating conditions 38 4 Visually inspect the suspected area and trace the leak path over the white powder c Black light and Dye Method A dye and black light kit for finding leaks is available Refer to the manufacturer s directions when using the kit Refer to the kit directions for the color of the fluid dye mix 1 Pour the specified amount of dye into the transmission fill tube 2 Operate the vehicle under normal operating conditions 3 Direct the black light toward the area suspected of leaking Dyed fluid will appear as a brightly colored path leading to the leak d Repairing the Leak Once the leak has been traced back to its source inspect the leaking part for the following conditions and repair the leaking part Gaskets Fluid level pressure is too high Plugged vent or drain back holes Improperly tightened fasteners or damaged threads Warped flanges or sealing surfaces Scratches burrs or other damage to sealing surfaces Damaged or worn out gasket Cracked or porous casting Improper sealant used where applicable e Seals Fluid level pressure is too high Plugged vent or drain back hole Damaged seal bore Damaged or worn out seal Improper seal installation Cracks in component Output shaft surface scratched nicked or damaged Loose or worn out bearing
22. Controls Troubleshooting Manual 1 Remove the cover from the transmission feedthrough connector and carefully connect the transmission external wiring harness Keep dirt and debris out of the connector 2 Connect the external wiring harness a For the 4000 Product Family connect engine turbine and output speed sensors retarder control connector if retarder is present and the retarder temperature sensor 72 4000 PRODUCT FAMILY 3000 PRODUCT FAMILY TU TO COOLER TO COOLER RETURN COOLER RETURN TORQUE 54 68 N m 40 50 Ib ft TORQUE 54 68 N m 40 50 Ib ft REAR VIEW REAR VIEW COOLER COOLER TO RETURN COOLER RETURN COOLER TORQUE 54 68 Nem 40 50 Ib ft TORGUE 34 47 Nem 25 35 Ib ft FRONT VIEW FRONT VIEW 020009 COOLER TO COOLER RETURN COOLER RETURN TORGUE 68 81 Nem 50 60 Ib ft TORGUE 68 81 Nem 50 60 Ib ft REAR VIEW REAR VIEW NOTE All torque values apply to cooler fittings RT Figure 6 2 Torque Values of Typical Fluid Cooler Lines 73 b For the 3000 Product Family connect engine and output speed sensors and the retarder control connector if retarder is present and unit was built before January 1998 For 3000 Product Family units with retarder built beginning January 1998 connect the retarder temperature thermistor the output speed sensor and
23. Nem 18 24 Ib ft Fluid fill tube bracket 24 29 Nem 18 21 Ib ft Control module pressure taps 10 13 Nem 7 10 Ib ft Cooler fittings 12 34 47 Nem 25 35 Ib ft 16 54 68 Nem 40 50 Ib ft 20 68 81 50 60 Ib ft Cooler port cover bolts 51 61 Nem 38 45 Ib ft Expansion plug prior to April 1997 1 2 Nem 9 18 Ib inch Flexplate adapter to converter cover bolts 33 39 Nem 25 29 Ib ft Output flange bolt s 3000 Product Family transmission 30 35 Nem 22 26 Ib ft 4000 Product Family transmission 51 61 Nem 38 45 Ib ft 3000 and 4000 Product Families Transmissions built after December 1 1998 70 80 52 59 Ib ft PTO cover bolts 51 61 38 45 Ib ft PTO mounting bolts 51 61 Nem 38 45 Ib ft Breather 12 16 Nem 9 12 Ib ft PTO pressure hose to transmission 10 13 Nem 7 10 Ib ft Rear cover bolts 90 110 Nem 66 81 Ib ft 76 TPS to transmission bracket M6 bolts 10 13 Nem 84 120 Ib inch 1 4 20 bolts 12 15 Nem 108 132 Ib inch Cooler Fluid Lines and Air Hose for No leaks Connection tightness Correct routing e Throttle sensor for Proper adjustment Correct routing of cable and harness Driveline for Proper indexing of universal joints Proper drive shaft angles Driveline backlash Lubricated universals and slip joints e Hydraulic System for Recommended fluid
24. QV3HHL SIHIS VE ONN 91 6201 i NV uatavav ur 8821 goze BLV1dX314 OL 3LV1dX314 1108 ul gpo 0 6661 418961 966 lt gt 14315 HALYVLS 30 gg 0g lt gt 21 e 22 gz lt gt M 5 1 av 16820 91 89 Cur 212 0768 ONISNOH T33HMATI 45222 0680 vez ualdvav 3LV1dXI14 40 19V4 ONILNNOW Cur pzez 16 09 4 66 18 4 829 ww 9 26 e a Figure 5 1 3000 Product Family Engine Adaptation 60 0 00 6560 41 69 16 WAN 88 Z 03 qunouu pesn sped epis UOISSIU SULZ Ji yoeduemod jou sped apis 5 Ji UUNULNU Wk SLNAWAYINOAY NOILVLdVdV 3NION3 WIVTD 39VdS H3l1H3ANOO NOISSINSNVYL A 416096 96 16 ualdvav LAVHSYNVYO NO 1014 A HOLVOIONI TWLOL 41010 00 WOWIXVIN 41 600 0 21 0 800 2 90072 uu U 64070 0072 a we NIW 410267 0079 1
25. amp 9 N Select a hold range that will limit road speed usually 274 or 3 range Never perform a driving stall test in reverse or low range seven speed models 6 Operate the engine at 100 percent full throttle maximum governed speed 7 With the engine at maximum governed speed begin gradually applying the vehicle service brakes while maintaining 100 percent full throttle When the vehicle comes to a complete stop record engine speed 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 two minutes to cool transmission fluid At the end of two minutes record converter out to cooler temperature 11 Proceed to Paragraph g Neutral Cool Down Check Procedure 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 49 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 pu
26. causing excess seal wear e Sealing Flange Inspect the sealing flange for bends Replace the sealing flange if bent 39 2 10 BREATHER a Location and Purpose The breather is located on top of the transmission converter housing The breather prevents air pressure build up within the transmission and its passage must be kept clean and open b Maintenance CAUTION DO NOT SPRAY STEAM WATER OR CLEANING SOLUTION DIRECTLY AT THE BREATHER Spraying steam water or cleaning solution at the breather can force water or cleaning solution into the transmission and contaminate the transmission fluid Seal all openings and vent assembly breather before spraying steam water or cleaning solution on the transmission The amount of dust and dirt encountered will determine the frequency of breather cleaning Use care when cleaning the transmission c Replacement Always use the correct wrench sized to remove or replace the breather Using pliers or a pipe wrench can crush or damage the breather stem and produce metal particles which could enter the transmission Tighten the breather to 12 16 Nem 9 12 lb ft 2 11 TROUBLESHOOTING a CHECK TRANS Light diagnostic codes NOTE Strip Pushbutton Shift Selectors cannot display or clear The CHECK TRANS light is usually located on the vehicle s instrument panel When the light is ON and the shift selector display is flashing shifts are being inhibited by the ECU
27. check for binding 3000 Product Family beginning with S N 6510184819 and 4000 Product Family beginning with S N 6610038064 Install flange or yoke onto output shaft Install the large O ring on the retainer plug Insert one bolt into the bolt hole in the plug Install a small O ring over the threads of the bolt so that the O ring seats against the retainer plug Install retainer plug and bolt into the flange or yoke Tighten bolt to 70 80 Nem 52 59 Ib ft 4 3 INSTALLING PTO Access to the PTO mounting pads and the space available to maneuver the transmission determine whether the PTO should be installed before or after the transmission 15 installed Use only the shims gaskets listed in the appropriate parts catalogs Refer to the Customer Service section Table 8 1 for the current publication number CAUTION DO NOT use cork or other soft gaskets to install the PTO NOTE DO NOT use sealing compounds they are usually incompatible with automatic transmission fluid 56 a Install Guide Pins Guide pins are included manufacturers installation kit Determine the reguired position of the guide pins in relation to the mounted position of the PTO The guide pins must align with the two blind holes in the PTO pad Install two headless guide pins into the converter housing PTO pad Tighten the pins b Install Gasket Install the special gasket over the guide pins ribbed surface away from the
28. engine fuel must be at the closed throttle position Install the pin cable end of the sensor to the engine fuel lever with brackets so that at the idle position the cable end is 11 17 mm 0 44 0 67 inch from its fully retracted position and at wide open throttle the cable end is pulled 15 2 22 9 mm 0 60 0 90 inch from the idle position Determine the stroke distance of the throttle sensor from closed to wide open Stroke distance must be from 15 22 9 mm 0 60 0 90 inch Recheck for zero clearance at the fuel lever Make sure that the 15 2 22 9 mm 0 60 0 90 inch dimension has not changed Design throttle sensor linkage brackets and levers to nominal dimensions so that the system stays within tolerance bands throughout its operating life NOTE The throttle position signal may be provided via communication link on electronically controlled engines 68 INSTALLING TRANSMISSION INTO Section VEHICLE 6 1 HANDLING a Preventing Damage Handle the transmission carefully to prevent damage to components in the installation path b Control of Transmission Movements Use a hoist or transmission jack that allows precise control of transmission movements during installation 6 2 MOUNTING TO ENGINE Use the following procedure to mount the transmission to the engine 1 Align one of the flexplate s bolt holes with the access opening in the engine flywheel housing 2 Lubricate the ce
29. move it through a full stroke Be sure the following conditions DO NOT EXIST Misalignment or obstruction to smooth movement through the full stroke e Idle and full throttle positions are not within an error zone refer to Figure 5 5 c Hitch Pin Throttle Position Sensor Installation Install the throttle sensor body as follows 1 Clamp cable end using clamp and shims refer to Figure 5 6 66 BENDING LOAD APPLIED MOUNTING PROVISION Use M6 x 1 00 or 74 20 in series bolts 3 places Torque x 1 00 bolt to 10 13 Nem 84 120 Ib in Torque 14 20 in series bolts to 13 14 108 132 Ib in Mount to a solid frame member Flatness of chassis mounting surface must not exceed 0 8 mm 0 03 in UNACCEPTABLE INSTALLATION 10 0 MAX INSTALLED OPERATING ANGLE IN ALL DIRECTIONS LOADING IN TENSION ONLY ACCEPTABLE INSTALLATION Attachment must provide freedom of motion to allow cable loading in tension only no bending loads WIRING HARNESS 55 0 mm 2 17 in MIN REQUIRED Fuel control must not move FOR CONNECTION the throttle sensor beyond REMOVAL the closed throttle position at any time FULLY EXTENDED FORCE REQUIRED FULLY 26 7 N 6 0 LB MAX RETRACTED 47 5 mm 1 87 in FULL THROTTLE 1181 mm 4 65 R 152 0 mm 6 00 in MIN ALLOWANCE RADIUS MOUNTING CLOSED THROTTLE LENGTH h NOTE Mounting length 952 mm 3 75 in 50 8
30. one bolt design 58 ASSEMBLY PADS DN TACHOGRAPH 6 On 2 EL 9g ENGINE 44 SPEED P TUA SENSOR E Wi FEEDTHROUGH 9 lt lt HARNESS gt 5 TO COOLER NAMEPLATE RETARDER CONNECTOR TEMPERATURE SENSOR SPEED SENSOR NOTE Inch Series Threads A FROM COOLER NOTE Inch Series Threads 07359 Figure 3 2 3000 Product Family Transmissions Disconnect Locations 54 TRANSMISSION PREPARATION Section 4 1 INSPECTING INPUT COMPONENTS a Bolt Holes Inspect all bolt holes on the front of the transmission and rear of the engine that are used in connecting the transmission to the engine The threads must be undamaged and the holes free of chips or foreign material b Pilot Boss Inspect the pilot boss at the center of the flywheel for damage raised metal that prevents free entry into the crankshaft hub or adapter Starter Ring Gear Inspect the starter ring gear for excessive wear damage d Transmission Mounting Flange Inspect the transmission mounting flange for raised metal dirt or if used pieces of gasket material e Transmission to Engine Mounting Inspect the transmission to engine mounting flange for raised metal burrs or pieces of gasket material if used Remove any of these defects Inspect the threaded holes for damaged threads 4 2 INSTALLING OUTPUT FLANGE OR YOK
31. the Allison DOCTM For PC service tool to the diagnostic tool connector on the wiring harness and scroll down the DIAGNOSTIC DATA LIST to read the OLS information Fluid Level Display Criteria As soon as fluid level information 18 requested the ECU determines if conditions are right to allow display Certain operating conditions must have been met for a period of two minutes before fluid level is displayed These operating conditions are Engine at idle Sump fluid at operating temperature 60 104 140 2209 Transmission output shaft stopped Transmission in neutral OLS functioning properly 21 a HOLD OVERRIDE BUTTON MODE INDICATOR X 8 MODE BUTTON lw N MODE 10 DIGITAL DISPLAY NL DISPLAY MODE EN DIAGNOSTIC BUTTON SIX SPEED LEFT HAND SIX SPEED RIGHT HAND LEVER SELECTOR LEVER SELECTOR DIGITAL DISPLAY MODE ID ush to enter diagnostic og mode and fluid level 218 check optional PUSHBUTTON oy gm DESENE STRIP PUSHBUTTON SELECTOR 5 SELECTORS NOTE Number displayed is highest forward range available in selected position Visually check to confirm range selected If display is flashing shift is inhibited M
32. transmission Mount the PTO Mount the PTO on the guide pins meshing the PTO driven gear with the transmission PTO drive gear Attach the PTO by installing a bolt in the top bolt hole Install the remaining bolts Tighten all bolts to 51 61 Nem 38 45 Ib ft 4 4 INSTALLING FILL TUBE AND SEAL a Location The 3000 Product Family fill tube may be mounted on either the right or left side The unused fill tube provision must have a plug to fill the tube opening The 4000 Product Family fill tube is on the right side CAUTION Install the fill tube bracket with the correct length bolt A bolt that is too long may cause cracks and leaks in the main housing Refer to the Customer Service section Table 8 1 for the appropriate parts catalog for the correct bolt b Installation Install the fill tube seal into the main housing Insert the fill tube through the seal Align the tube bracket with its bolt location Install the fill tube bolt and tighten to 24 29 Nem 18 21 10 ft On all 3000 Product Family transmission models before S N 6510107518 install the expansion plug in the unused fill tube hole if the plug is reusable Tighten the plug to 1 2 Nem 9 18 inch On all 3000 Product Family transmission models beginning with S N 6510107518 the unused hole is blocked using a fill tube seal and a new plug Install the fill tube seal into the unused fill tube hole Install the new plug so that the underside o
33. use in Allison transmissions look for fluid license or approval numbers on the container or consult the lubricant manufacturer Consult your Allison Transmission dealer or distributor before using other fluid types When choosing the optimum viscosity grade of fluid duty cycle preheat capabilities and or geographical location must be taken into consideration Table 2 4 lists the minimum fluid temperatures at which the transmission may be safely operated without preheating the fluid Preheat with auxiliary heating equipment or by running the equipment or vehicle with the transmission in neutral for a minimum of 20 minutes before attempting range operation Table 2 4 Transmission Fluid Operating Temperature Requirements Ambient Temperature Below Which Preheat is Required Viscosity Grade TranSynd SAE 0W 20 e 2 SAE 10W _ _ A 27 Table 2 4 Transmission Fluid Operating Temperature Requirements Ambient Temperature Below Which Preheat is Reguired Viscosity Grade Fahrenheit SAE 15 40 5 3 SAE 30W ___0 __ __ 2 40W Arctic as defined by MIL L 46167B Ref SIL 13 TR 90 2 6 TRANSMISSION FLUID AND FILTER CHANGE INTERVALS a Frequency determined by the severity of transmission service More frequent changes may be necessary than recommended in the general guidelines CAUTION Transmission fluid and filter change frequency is wh
34. 0 HOLNTO ONILVLOH ONISNOH YALYSANOD JINON ONISNOH STOH1NO9 15373 JINON 1081 JINdOWN 14 FINGOW NOLSId 59 JINdoW LAVAS 1nd1nO JINON A 1112 NNS NNS LAVHS NIYIN JINdoW LAVHS 3NIdunl V JINGOW H3183ANO9 HOLNT9 HOLNTD 9 did 110 SNISNOH NIVIN 140ddnS LNOHJ JINGOW ONISNOH NIYIN 31ndOW 10 1404405 LNOYS Figure 1 2 3000 Product Family Transmission Cross Section 00907 82 0 STOHLNO9 0819373 JINON 103109 Ld JINGOW d NNS NNS 1JVAS 31ndOW 14 5 NIVIN 31nqow uaquviad 5 ANIGYNL 1019 29 HOLNTD 9 JINON 21112 ONILVLOH 5 H3183ANO2 FINGOW SNISNOH H31H3ANOO9 E 2227 55 80108 59 55
35. 0 08 000 08 000 08 S N 00006 SETA 00006 SSIHALOOO OST SOMN 00006 meyrao SAN 000 0S SANN 000 0S S67 SAL n PUASULAL pue 0 6 N d 31 1919 yout IMPON 09000 your uyur amp reyxny pum aqu pan 2 SN NOLLVOOA NOLLVOOA 1 0007 104 5 1eyr4 pin 4 79 2 olgel 31 b Abnormal Conditions Transmission fluid must be changed whenever there is evidence of dirt in the fluid or the fluid is discolored which indicates a high temperature condition Fluid analysis will also reveal a high temperature condition Local conditions severity of operation or duty cycle may require more or less frequent fluid or filter changes c Fluid Analysis Transmissions used in high cycle rate applications should have a fluid analysis performed to be sure of the proper change interval Transmission protection and fluid change intervals can be optimized by monitoring fluid oxidation according to the tests and limits shown in Table 2 7 Consult your local telephone directory for fluid analysis firms To be sure of consistent and accurate fluid analysis use only one fluid analysis firm R
36. 04 sounqoeynuew 108002 1109 14 6 3 419 10 MIIA 995 Keme 640 0 85 0 1 ap s no ayeldxay nse1 jjeus ur 8081 26 5 ualdvav 31V1dX314 NO ONIGVSY HOLVOIGNI TVLOL WAWIXYIN 500 0 40 9196 95 WN 62 69 0 910101 5 X X OLIN 9 10 62 52 66 26 0 6071 X 88 21 ualdvav 1 14 314 01 31 14 374 1108 01 34 80 1109 2 VZ ONN tli S V 0 1108 81 67 86 19 16 0 0360 51108 9 01 X OLN 31 NIN 1108 12 8 01 8 h 1108 82 1 T 5399 D 7 1 ONISNOH 133 4 lt 412670 0921 ONISNOH 30 39V4 ONILNNON 3NIIH31N39 L3VHSXNVHO ualdvav ANH LJVHSyNVHO SNIQV3H HOLVOIINI 79101 WAWIXWIN ut 00070 40 ualdvav LdVHSNNVHO 41 62 52 WN 68 66 0 onbuol 86 0 0 52 x sz LX uonisod ubisep Jeydepe 10 ees 61070 geo
37. 3 3 UNCOUPLING FROM DRIVELINE ENGINE AND VEHICLE 3 4 REMOVING THE TRANSMISSION 3 5 REMOVING OUTPUT FLANGE YOKE SECTION TRANSMISSION PREPARATION 4 1 INSPECTING INPUT COMPONENTS 4 2 INSTALLING OUTPUT FLANGE OR YOKE 4 3 INSTALLING PTO ep ge ge ii 4 4 INSTALLINGFILLTUBEANDSEFAL 4 5 INSPECTING PLUGS AND OPENINGS SECTION V PREPARING VEHICLE FOR TRANSMISSION 5 1 5 2 5 3 5 4 5 5 INSTALLATION ENGINE TRANSMISSION ADAPTATION REQUIREMENTS CHECKING FLEXPLATE DRIVE ASSEMBLY CHASSIS AND DRIVELINE INSPECTION COOLER AND LINES po cesa a INSPECTING CONTROLS 4A E TRAE OUR B SECTION VI INSTALLING TRANSMISSION INTO VEHICLE 6 1 6 2 6 3 6 4 6 5 6 6 6 7 6 8 6 9 HANDLING MOUNTING TO ENGINE 225222552595 INSTALLING TRANSMISSION MOUNTING COMPONENTS COUPLING TO DRIVELINE uu o RR R9 CONNECTING OUTPUT RETARDER ACCUMULATOR CONNECTING POWER TAKEOFF CONTROLS CONNECTING PARKING BRAKE CONTROL CONNECTING COOLBR oae harm RR CR den CONNECTING ELECTRICAL COMPONENTS 6 10 CONNECTING SPEEDOMETER DRIVE 6 11 FILLING HYDRAULIC SYSTEM 6 12 INST
38. AL DAMPER XA BOTH SIDES NOTE Inch Series Threads PTO PROVISION AVAILABLE BOTH SIDES LEFT FRONT VIEW V07289 02 00 Figure 1 6 3000 Product Family Transmission with PTO 13 BREATHER ASSEMBLY PADS FEEDTHROUGH HARNESS CONNECTOR 6 SPEED SENSOR RA Sous 2 9 2 T MAIN PRESSURE TAP NOTE Inch Series Threads RIGHT REAR VIEW COOLER PORTS NOTE Inch Series Threads BREATHER ASSEMBLY PADS BOTH SIDES OUTPUT J RETARDER TORQUE CONVERTER WITH LOCKUP CLUTCH AND TORSIONAL DAMPER 7 ACCUMULATOR 4 OIL FILL TUBE AND x DIPSTICK AVAILABLE ON BOTH SIDES MAIN PRESSURE TAP NOTE Inch series threads LEFT FRONT VIEW V07290 01 00 Figure 1 7 3000 Product Family Transmission with Retarder 14 m Z 7 lt lt ASSEMBLY PADS FEEDTHROUGH HARNESS CONNECTOR OUTPUT SPEED SENSOR RETARDER VALVE BODY CONNECTOR MAIN PRESSURE TAP NOTE Inch Series Threads TACHOGRAPH PROVISION NOTE Metric Series Threads SPEEDOMETER PROVISION COOLER PORTS NOTE Inch Series Threads NOTE Inch Series Threads LEFT REAR VIEW ASSEMBLY PADS BOTH SIDES BREATHER TORGUE CONVERTER WITH LOCKUP CLUTCH AND TORSIONAL DAMPER OUTPUT yf RETARDER ACCUMULATOR FILL TUBE AND DIPSTICK MAIN PRESSURE TAP AVAILABLE ON NOT
39. ALLATION INSPECTION LIST SECTION VII INSPECTIONS AND ADJUSTMENTS 7 1 7 2 INSTALLATION INSPECTION LIST ROAD TEST AND VEHICLE OPERATION INSPECTION LIST SECTION VIII CUSTOMER SERVICE 8 1 8 2 OWNER ASSISTANCE e ie SERVICE LITERATURE uo kom Gs TRADEMARK USAGE The following trademarks are the property of the companies indicated Allison DOC M is trademark of General Motors Corporation e DEXRON is a registered trademark of the General Motors Corporation TranSynd M is a trademark of Castrol Ltd LPS Electro Contact Cleaner is a registered trademark of LPS Laboratories WARNINGS CAUTIONS NOTES IT IS YOUR RESPONSIBILITY to be completely familiar with the warnings and cautions described in this handbook It is however important to understand that these warnings and cautions are not exhaustive Allison Transmission could not possibly know evaluate and advise the service trade of all conceivable ways in which service might be done or of the possible hazardous consequences of each way The vehicle manufacturer is responsible for providing information related to the operation of vehicle systems including appropriate warnings cautions and notes Consequently Allison Transmission has not undertaken any such broad evaluation Accordingly ANYONE WHO USES A SERVICE PROCEDURE OR TOOL WHICH IS NOT RECOMMENDED BY ALLISON TRANSMISSIO
40. ATE FLEXPLATE ASSEMBLY FLEXPLATE ADAPTER V00533 00 04 5 3 Figure 5 4 Arrangement of Adaptation Components CHASSIS AND DRIVELINE INSPECTION Inspect the chassis and driveline components for the following conditions and correct them as appropriate Transmission mounts broken or worn out Bolts and other hardware damaged missing or incorrect Isolators rubber mounts damaged or missing Driveline angles runout or balance which does not conform to the manufacturer s recommendations Driveline yoke slip joints freedom of movement damaged or worn out correctly lubricated correctly indexed Driveline midship or hanger bearings damaged or misaligned 63 Universal joints freedom of movement damaged or worn out correctly lubricated correctly indexed e Vehicle differential backlash manufacturer s specification Universal joint coupling alignment and differential damage Cross frame members and rear support members condition and location e PTO driven equipment shafts and couplings damaged or misaligned e Auxiliary transmission shaft alignment alignment of yoke or flange backlash fluid leaks 5 4 COOLER FILTER AND LINES a Inspection Perform the following and correct any faulty conditions e Transmission fluid cooler and related coolant lines Inspect for contamination clean and flush as necessary Inspect for deter
41. C VEHICLE AIR SUPPLY HOSE VEHICLE ACCESSORY AND MOUNTING w 5 PRESSURE than 0 9 m 3 ft and is not present T VALVE 85 PSIG i MAXIMUM CLOSING PRESSURE T Aera Be sure there is an Tie down center NORMALLY ounce fitting on IN CAB of hose if longer CLOSED 00 installations TRANSMISSION CONTROLS T on T200 T300 installations V07302 00 02 Figure 6 1 3000 And 4000 Product Families Output Retarder Accumulator Installation 1 Connect the air supply hose fitting to the retarder air control solenoid Tighten the fitting to 16 22 Nem 12 16 Ib ft 2 Connect the hydraulic hose between the retarder and the accumulator Tighten hose fittings to 68 81 Nem 50 60 Ib ft NOTE Be sure a pressure protection valve is correctly installed between the vehicle brake air system and the accumulator control solenoid 6 6 CONNECTING POWER TAKEOFF CONTROLS If not already mounted mount the PTO s onto the transmission refer to Section 4 3 Installing PTO 1 Inspect the PTO harness routing for kinks and sharp bends Avoid routing the cable close to exhaust pipes or manifold The PTO harness must not rub or interfere with adjacent parts 2 Connect controls to the PTO 3 Determine if PTO control operation is correct 71 gear mu
42. E a Output Oil Seal Inspect the output oil seal for leaks or damage Refer to Customer Service Section Table 8 1 for the appropriate service manual for replacement instructions If not replacing the oil seal lubricate it with high temperature grease or transmission fluid CAUTION DO NOT attempt to polish the oil seal contact surface on the flange or yoke Scratches or machine type lead can cause the seal to leak b Inspect Flange or Yoke Inspect flange or yoke for damage or wear The oil seal contact surface must be smooth and regular to prevent oil leaking past the seal Rotate the flange after installation to be sure that the flange isn t binding 55 Install Output Flange Yoke 3000 Product Family before S N 6510184819 and 4000 Product Family before S N 6610038064 Install flange or yoke onto output shaft Install the large O ring on the retainer plug Install a belleville washer on each bolt so that the coned end of the washer contacts the underside of the bolt head Insert two bolt washer assemblies into the bolt holes in the plug Install a small over the threads of each bolt so that the O ring seats against the retainer plug Install retainer plug and bolts into the flange or yoke Tighten bolts to 30 35 Nem 22 26 ft for a 3000 Product Family transmission Tighten bolts to 51 61 Nem 38 45 Ib ft for a 4000 Product Family transmission Rotate the flange or yoke to
43. E Inch series threads BOTH SIDES LEFT FRONT VIEW V07300 01 00 Figure 1 8 3000 Product Family Transmission with Retarder and Provisions for Tachograph and Speedometer 15 BREATHER ASSEMBLY PADS FEEDTHROUGH HARNESS OUTPUT SPEED SENSOR RETARDER VALVE BODY MAIN PRESSURE TAP NOTE Inch Series Threads TACHOGRAPH PROVISION COOLER PORTS NOTE Inch Series Threads NOTE Inch Series Threads LEFT REAR VIEW ASSEMBLY PADS BOTH SIDES BREATHER TORQUE CONVERTER WITH LOCKUP CLUTCH AND TORSIONAL DAMPER OUTPUT RETARDER TO RETARDER ACCUMULATOR OIL FILL TUBE AND DIPSTICK MAIN PRESSURE TAP AVAILABLE ON NOTE Inch series threads BOTH SIDES LEFT FRONT VIEW V07401 02 00 Figure 1 9 3000 Product Family Transmission with Retarder and Provisions for Tachograph and Sump Cooler 16 TOP RIGHT POSITION MOUNTING TURBINE SPEED SENSOR il T EN 22 CE gt 2 2 1 0 NI AT z 7 FEEDTHROUGH HARNESS JJ pee FILL TUBE NAMEPLATE REAR VIEW ZEN SENSOR OUTPUT SPEED COOLER PORTS RIGHT FEEDTHROUGH HARNESS CONNECTOR 7 CR M 5 6 Ex lt 7V OOO 2997 J MOUNTING PAD BOTH SIDES M A S ALES
44. N 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 The following three types of headings are used in this manual to attract your attention WARNING A warning is used when an operating procedure practice etc if not correctly followed could result in personal injury or loss of life CAUTION A caution is used when an operating procedure practice etc if not strictly observed could result in damage to or destruction of equipment NOTE A note is used when an operating procedure practice etc is essential to highlight INTRODUCTION 1 1 ABOUT THIS MANUAL This handbook is a mechanic s reference for maintaining removing or installing the 3000 and 4000 Product Families on highway transmission with a WTEC HI control system WTEC controls were optional on the 3000 and 4000 Product Families on highway transmission units built in 1997 but became standard on units built starting in 1998
45. arnesses due to poor routing chafing excessive heat tight bends etc Improperly mounted electronic control components Poor connector seals where applicable Exposed harness wires EMI generating components and accessories Loose ground connections 44 help 1 intermittents it sometimes helps to place the appropriate tester the suspected component or circuit and simulate operating conditions wiggle pull bump and bend while watching the tester g Exiting Diagnostic Mode NOTE Strip Pushbutton Shift Selectors cannot display or clear diagnostic codes To exit the diagnostic mode do one of the following Do nothing wait until the calibrated time has passed and the system automatically returns to normal operation Using a pushbutton shift selector simultaneously press the Up and 4 Down arrow buttons Using a pushbutton shift selector press Neutral Using a lever shift selector press the DISPLAY MODE button once e Using a lever shift selector move the selector lever to any position other than the one it was in when the diagnostic display mode was activated 2 12 STALL TEST AND NEUTRAL COOL DOWN HECK a Purpose Stall testing is performed to determine if a vehicle performance complaint is due to an engine or transmission malfunction Stall testing is a troubleshooting procedure only never perform a stall test as a general test or during r
46. blished stall speed e If engine speed with the transmission stalled is more than 150 rpm below the stall speed specification an engine issue is indicated e If engine stall speed is more than 150 rpm above specification a transmission issue is indicated Conditions that can exist to cause stall speed to 150 rpm above specification could be Transmission fluid cavitation or aeration Verify proper fluid level using the oil level sensor if equipped or dipstick Slipping clutch Torque converter malfunction Sticking or damaged torque converter valve e A low stall speed at least 33 percent lower than published stall speed could indicate an engine issue or a freewheeling stator in the torque converter 50 REMOVING TRANSMISSION 3 1 DRAINING TRANSMISSION Drain the transmission fluid before removing the transmission from the vehicle 1 Remove the drain plug from the oil pan Examine the drained fluid for evidence of contamination refer to Section 2 7 TRANSMISSION FLUID CONTAMINATION Paragraph a Fluid Examination Reinstall the drain plug 2 Remove the transmission fill tube if it interferes with transmission removal Plug the fill tube hole in the main housing to keep dirt from entering the transmission NOTE A significant amount of fluid may drain from the hydraulic lines when they are disconnected from the transmission 3 Disconnect all hydraulic lines from the transmission Remove t
47. cle Counter reaches 25 e The Event Counter counts the number of occurrences of a diagnostic code If a code is already in the code list and the code is again detected that code is moved to position 41 the active indicator is turned on the Ignition Cycle Counter is cleared and 1 is added to the Event Counter You can access the ignition cycle counter and event counter information through the Allison DOC For PC Service Tool c Clearing Trouble Codes Using Shift Selector NOTE Note Strip Pushbutton Shift Selectors cannot display or clear diagnostic codes During installation false codes can be recorded in the electronic control s memory Clear these codes before road testing the vehicle Use the shift selector to clear the codes refer to Figure 2 4 Pushbutton shift selectors Enter the diagnostic mode by pressing the Up and Down arrows simultaneously Simultaneously press both buttons twice if there is an oil level sensor present Lever shift selector enter the diagnostic mode by momentarily pressing the DISPLAY MODE button Press twice if there is an oil level sensor present To clear all active indicators press and hold the MODE button approximately 3 seconds until the mode indicator LED flashes To remove all codes press and hold the MODE button for approximately 10 seconds until the mode indicator LED flashes again 42 4 Retrieving Troubleshooting Codes diagnostic codes NOTE
48. e Rust or pitted transmission parts Transmission fluid spewing out of transmission breather Transmission fluid in radiator Gaskets blistered or wrinkled in uncompressed areas Appearance of fluid presence of water causes a cloudy or gray pink or strawberry colored fluid Steam from the breather For additional field analysis information refer to Allison Transmission publication number GN2055EN Automatic Transmission Fluid Technician s Guide Use this publication to review testing methods and limits of water glycol content d Metal Metal particles in the fluid except for minute particles normally trapped in the oil filter indicate internal transmission damage If these particles are found in the sump the transmission must be disassembled and closely 34 inspected to find their source Metal contamination reguires complete transmission disassembly Clean all internal and external hydraulic circuits cooler and all other areas where the particles could lodge 2 8 TRANSMISSION FLUID AND FILTER CHANGE PROCEDURE a Drain Fluid NOTE Do not drain the transmission if replacing only the filters WARNING Avoid contact with hot fluid or the sump when draining transmission fluid Direct contact with hot fluid or the hot sump may result in bodily injury 1 Drain the fluid when the transmission is at the normal operating sump temperature of 71 93 160 F 200 F Hot fluid flows quicker and drains more comp
49. e literature is available as shown in the following table This service literature provides fully illustrated instructions for the operation maintenance service overhaul and parts support of your transmission To be sure that you receive maximum performance and service life from your transmission you may order publications from SGI Inc Attn Allison Literature Fulfillment Desk 8350 Allison Avenue Indianapolis IN 46268 TOLL FREE 888 666 5799 INTERNATIONAL 317 471 4995 80 Table 8 1 Available Service Literature 3000 Product 3000 Product Family 4000 Product Transmission Model Family 7 5 amil Allison DOC User GN3433EN GN3433EN GN3433EN Guide Automatic Transmission GN2055EN GN2055EN GN2055EN Fluid Technician s Guide Job Aid Cards JA3426EN JA3426EN JA3427EN Operator s Manual OM2995EN OM2683EN 2095 Owner s Manual OM3349EN OM3349EN Parts Catalog PC2150EN PC2150EN PC2456EN Parts Catalog CD ROM CD2150EN CD2150EN CD2456EN Principles of Operation PO2454EN PO2454EN PO2454EN Service Manual SM2148EN SM2148EN SM2457EN Electronic TS2973EN Troubleshooting Manual Worldwide Sales and SA2229EN Service Directory Also Available On The Internet At www allisontransmission com Family 81 O AL MT3004EN 200603 www allisontransmission com Printed in USA 200605
50. efer to the Technician s Guide for Automatic Transmission Fluid GN2055EN for additional information Table 2 7 Fluid Oxidation Measurement Limits 25 change from new fluid Total Acid Number 3 0 change from new fluid 2 percent by volume maximum mg of potassium hydroxide KOH to neutralize a gram of fluid 2 7 TRANSMISSION FLUID CONTAMINATION a Fluid Examination The presence of fluid contamination in an automatic transmission can be detrimental to continued operation A normal amount of condensation will appear in the fluid during operation At each fluid change examine the drained fluid for evidence of dirt or water Contamination limits are shown in Table 2 8 Glycol No trace allowed Alien fluids If detected change transmission fluid Any fluid not included on the Allison Approved Fluid List The Approved Fluids Lists may be found at the Allison Transmission website www allisontransmission com b Monitoring Wear Absolute maximum values cannot be applied to wear metals of an automatic transmission due to the many variables present that affect concentration limits Wear metal analysis results must be evaluated using a trendline approach A trendline approach plots the concentration level of each wear metal over a period of time A minimum of four data points for each metal is required to establish a trendline A line of best fit drawn through the plotted points 15 32 considered trendline Cau
51. ehicle Inspect the vehicle to identify the source of the leak Refer to the following list for possible points of transmission fluid leaks and their causes 37 Transmission mating surfaces Attaching bolts not correctly aligned Improperly installed or damaged gasket Mating surface s damaged Housing leak Fill tube or plug seal damaged or missing Fill tube bracket dislocated Oil cooler connector fittings loose or damaged Output shaft seals worn out or damaged Pressure port plugs loose Porous casting e Leak at converter end Converter seal damaged Seal lip cut check converter hub for damage Garter spring missing from seal Converter leak in weld area or O ring seal Porous casting e Fluid comes out of fill tube Overfilled incorrect dipstick Plugged vent Water or coolant in fluid fluid appears milky Incorrect electronic fluid indication Drain back holes plugged 3 Visually inspect the suspected area Inspect all gasket mating surfaces for leaks 4 If the leak still cannot be identified clean the suspected area with a degreaser steam or spray solvent Clean and dry the area 5 Operate the vehicle for several miles at varying speeds Inspect the vehicle for leaks 6 If the leak source still cannot be identified use the powder method and or the black light and dye method as explained below Powder Method 1 Clean the suspected area 2
52. en operating conditions create high levels of contamination or overheating Table 2 5 and Table 2 6 Recommended Fluid Filter Change Intervals is a general guide for fluid and filter change intervals 28 sj 1990 s eA1ojur posde o 10 5 oSeo rur 10 ye aq 18 SIAPA sisA eue osn pezrundo oq s eA1ojut pue 1014 uorssrusue1 10188 151611 uosi y JO s eA1ojur 8 ping pousi qnd 1ogrp speA1ojur sso 10 Jo UOTE20A 91949 UI PASI JOU 5 12410 pue 194 401 euo enbo 10 559 o o o tad 401 ouo uey 1978913 9J949 pue asnjoy AVPMYSTIH YO UO SINOH 0006 SINOH 0006 SINOH 0007 SINOH 0006 SINOH 0006 S noH 000 SIUC 96 oc 96 SWC 96 9c 000 021 000 Oc D 000 OFZ 000 021 000 Oc D 000 021 SON 000 51 1184790 SOTA 000 Z SPINAL 000 051 SOIN 000 SL SON 000 Z SATIN 000
53. ets b Install the thermocouple and connect the leads 9 Install and connect other electrical components such as heaters a If equipped install the pressure gauge tube or line b Be sure that all unused hydraulic openings are plugged 6 10 CONNECTING SPEEDOMETER DRIVE The ECU through the VIM provides an electronic speedometer speed signal If used consult the OEM for connection procedures 74 6 11 FILLING HYDRAULIC SYSTEM 1 Select transmission fluid refer to Section 2 5 FLUID RECOMMENDATTONS 2 Fill the transmission with the reguired amount of fluid refer to Table 2 9 3 Run the engine for about one minute and check the fluid level refer to Section 2 3 TRANSMISSION FLUID TEST Paragraph Cold Test Procedure 6 12 INSTALLATION INSPECTION LIST Complete the Installation Inspection List Refer to Section 7 Inspections and Adjustments 75 INSPECTIONS AND ADJUSTMENTS Section 7 1 INSTALLATION INSPECTION LIST Use this inspection list after transmission installation As items are confirmed mark them off this list Torque Values All control module bolts 51 61 Nem 38 45 Ib ft Speed sensor bolts 24 29 Nem 18 21 Ib ft Flexplate to crankshaft hub bolts Consult Engine Manufacturer Specifications Flexplate to flexplate adapter bolts 12 bolt design 33 39 Nem 25 29 Ib ft 6 bolt design 63 73 Nem 46 54 Ib ft Fluid drain plug 25 32
54. f contamination and possibly a clue as to its source A minimal amount of water and glycol may be due to one or all of the following e Uncovered oil drums Open transmission fill tube Glycol from an all purpose fill container e Defective transmission oil cooler Do not use fluid contaminated by water regardless of whether it contains glycol if the water is greater than 0 2 percent by volume of fluid 33 CAUTION If the transmission fluid is contaminated by water at a volume greater than 0 2 percent or by any trace of ethylene glycol disassemble the transmission and replace the following e Seals Gaskets e Clutch Plates e Bearings Torgue converters that cannot be disassembled Components that have rusted Solenoids that do not meet resistance specifications Remove all traces of ethylene glycol and varnish deposits Failure to follow this procedure decreases transmission reliability and durability CAUTION After flushing the cooler test the external cooler circuit for restrictions If circuit pressure drop is above specifications the cooler has trapped particles and must be replaced Nelco Company offers a kit that detects presence of ethylene glycol in transmission fluid The kit is identified as GLY TEK Test Kit and can be obtained from Nelco Company 1047 McKnight Road South Saint Paul Minnesota 55119 651 738 2014 Some conditions that may indicate water and or glycol in the fluid ar
55. f the plug head contacts the fill tube seal This plug and seal may be used on earlier units when the expansion plug is not reusable 57 4 5 INSPECTING PLUGS AND OPENINGS Carefully inspect all sides and the bottom of the transmission for loose or missing plugs Pressure Plugs Determine if 0 4375 20 UNF 2A pressure plugs are tightened to 10 13 Nem 7 10 lb ft b Fluid Drain Plug Determine that the drain plug is tightened to 25 32 Nem 18 24 Ib ft c Cleanliness Inspect the openings into which the cooler lines connect for deformities or obstructions Inspect the transmission electrical connectors for cleanliness Clean electrical connectors with LPS Electro Contact Cleaner only 58 PREPARING VEHICLE FOR TRANSMISSION Section V YO INSTALLATION 5 1 ENG NE TRANSMISSION ADAPTATION REGUIREMENTS You must make sure a new transmission installation can be adapted to the vehicle s engine Use the measurements described in this section for correct transmission to engine adaptation Refer to Figure 5 1 or Figure 5 2 and or 567 020 Typical arrangement of adaptation components is shown in Figure 5 4 a Measuring Equipment The following measuring equipment is required 600 mm 24 inch precision caliper e 50 100 mm 2 4 inch telescoping gauge 25 76 mm 1 3 inch outside micrometer e Dial indicator and mounting attachments base posts and clamps 0 150 mm 0 6 inch depth micrometer
56. ght should go off should appear in the shift selector display Clear Trouble Codes during installation it is common for false codes to be stored in the electronic control s ECU These codes must be cleared prior to road testing the vehicle Road Test the Vehicle allow the electronic control time to converge shifts Determine Proper Operation inspect all components for proper mounting and operation and inspect for transmission fluid leaks at gasket surfaces lines and hoses Determine new Trouble Codes use the Allison DOC For PC Service Tool or shift selector to determine if codes were set during the road test Refer to Section 2 11 TROUBLESHOOTING Paragraph Clearing Trouble Codes Using Shift Selector and Paragraph d Retrieving Troubleshooting Codes Troubleshoot if codes exist after the road test problems must be found and corrected refer to TS2973EN WTEC III Troubleshooting Manual b Service and Maintenance Refer to the current issue of the 3000 and 4000 Product Families service manuals for detailed transmission service and maintenance instructions Refer to the latest issue of the WTEC Troubleshooting Manual for detailed electronic control system troubleshooting Refer to the Customer Service section Table 8 1 for the latest publication number 78 Road Test Inspection List Complete the following checklist Neutral Start Circuit Starts only in neutral Instrumen
57. he lines from the vehicle if they interfere with transmission removal Plug all openings to keep dirt from entering the hydraulic system 4 If an integral cooler is used drain coolant from cooler and disconnect coolant hoses Remove the hoses from the vehicle if they interfere with transmission removal Plug all openings to keep dirt from entering the cooling system 3 2 DISCONNECTING CONTROLS 1 Disconnect or completely remove controls If controls are not removed from the transmission position them so that they do not interfere with transmission removal 2 Disconnect the external wiring harness at the feedthrough harness connector Refer to Figure 3 1 or Figure 3 2 Prevent dirt or moisture from entering a disconnected connector Position the wiring harness so it does not interfere with transmission removal For the 3000 Product Family transmissions disconnect the input engine and output speed sensors For the 4000 Product Family transmissions disconnect the input engine turbine and output speed sensors refer to Figure 3 1 51 NOTE There may be residual transmission fluid the retarder accumulator hydraulic line 3 If a retarder is used disconnect the retarder accumulator hydraulic line from the retarder Disconnect any cooling lines For 3000 Product Family transmissions built before January 1998 disconnect the transmission external harness from the retarder connector If used discon
58. heir meaning are Table 2 2 Invalid For Display Codes Display Sequence Interpretation of Display oL 5 0 Engine rpm too low oL 5 9 Engine rpm too high oL 6 5 Neutral not selected oL 7 0 Sump fluid temperature too low oL 7 9 Sump fluid temperature too high oL 8 9 Output shaft rotation oL 9 5 Sensor failure NOTE Report sensor failure to a distributor or dealer in your area Consult the telephone directory for the Allison Transmission distributor or dealer near you The countdown is restarted when the condition causing the invalid for display code 59 has been corrected The countdown is not restarted if there isa momentary increase in engine rpm which may generate a code 59 Invalid for display messages are as follows Allison DOC Display Invalid for display messages are displayed in the Oil field of the Data Monitor Allison DOC Message OL SETTLING TIME X OL ENGINE SPEED LO OL SPEED OL SELECT NEUTRAL OL SUMP TEMP LO 23 Allison DOC Message OL SUMP TEMP HI OL OUTPUT SPEED HI OL CHECK CODES e Exiting the Fluid Level Mode Exit as follows For a pushbutton shift selector press the N Neutral pushbutton once For a lever selector press the DISPLAY MODE DIAGNOSTIC button once or move the lever to a range position Allison DOC does not use a special Fluid Level Mode b Manual Fluid Test Procedure
59. ioration Inspect for faulty connectors or kinks Clean and flush transmission fluid cooler both coolant and oil sides Pressure test both sides using a 276 kPa 40 psi air supply e Hydraulic lines Inspect for contamination clean and flush as necessary Inspect for deterioration Inspect for faulty connectors or kinks b After Overhaul A complete cleanup of the transmission system after an overhaul cannot be assumed Repeated cleaning and flushing may not remove all debris from the transmission fluid cooler system Replace the transmission from cooler lube filter after 5000 miles 8000 km Refill the transmission to the correct fluid level refer to Section 2 3 TRANSMISSION FLUID TEST 64 5 5 INSPECTING CONTROLS a Inspection Inspect the following and correct any faulty conditions e Shift selector improper operation poor electrical connections improper harness routing Cab and chassis wiring harness poor electrical connections frayed insulation wiring damage e Throttle sensor components if present freedom of movement improper routing bellows damage improper or loose cable mounting e PTO controls if present damage wear improper operation lubrication electrical harness connections and wiring damage e Temperature gauge capillary tube damage if used sensor damage Retarder Controls damage wear poo
60. king brake the service brake and chock the wheels securely Warn personnel to keep clear of the vehicle and its travel path 46 Performing Transmission Stall Test 1 Start the engine While in neutral let the transmission warm to normal operating temperature Sump temperature 71 93 160 200 Converter out temperature 82 104 180 220 F 2 Determine the hot transmission fluid level and adjust as necessary 3 Turn OFF all engine accessories 4 Place the Allison DOC diagnostic tool in clutch test mode Use the shift selector to select 4 range Using 4 range reduces the torque imposed on the transmission driveline Do not perform a transmission stall test in reverse CAUTION To help avoid transmission or driveline damage full throttle stall tests must not be performed in R Reverse range all models or low ranges 7 speed models 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 CAUTION The transmission stall test procedure causes a rapid rise in e 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 de
61. l and allow the engine to idle 500 800 rpm 24 4 With the engine running remove the dipstick from the tube and wipe the dipstick clean 5 Insert the dipstick into the tube until it stops and then remove Read the fluid level Repeat the test procedure to verify the reading 6 If the fluid level is between the COLD ADD and the COLD FULL bands refer to Figure 2 2 the transmission may be operated until the fluid is hot enough to perform a HOT test If the fluid level is not between the COLD ADD and the COLD FULL bands add or drain fluid as necessary to bring it to the middle of this level 7 Perform a hot test at the first opportunity after the normal operating sump temperature of 71 C 93 C 160 F 200 F is reached d Hot Test Procedure the transmission in D Drive until normal operating temperatures are Sump temperature 71 C 93 C 160 200 Converter out temperature 82 C 104 C 180 220 2 Park the vehicle on a level surface and shift to N Neutral Apply the parking brake and chock the wheels Allow the engine to idle 500 800 rpm 3 With the engine running remove the dipstick from the tube and wipe clean 4 Insert the dipstick into the tube until it stops Then remove it Read fluid level 5 Repeat the test procedure to verify the reading dipstick The HOT RUN band is between the
62. letely 2 Remove the drain plug from the oil pan and allow the fluid to drain into a suitable container 3 Examine the fluid as described in Section 2 7 TRANSMISSION FLUID CONTAMINATION Paragraph a Fluid Examination b Replace Filters Refer to Figure 2 3 For 3000 Product Family before S N 6510069120 1 Remove twelve bolts 1 two filter covers 2 two O rings 5 two square cut seals 4 and two filters 6 from the bottom of the control module 2 When installing parts lubricate and install new O rings 5 on each cover 2 Install a square cut seal 4 on each cover 2 Lubricate filter O ring inside filter and install filters 6 onto covers 2 35 4000 PRODUCT FILTER 3000 PRODUCT FAMILY COVER V03532 02 02 Figure 2 3 Location of Filters for Service For 3000 Product Family beginning with S N 6510069120 and 4000 Product Family beginning with S N 6610009730 1 Remove twelve bolts 1 two filter covers 2 two gaskets 3 two O rings 4 two O rings 5 and two filters 6 from the bottom of the control module 2 When reinstalling parts lubricate and install new O rings 4 and 5 on each cover Lubricate O ring inside filter 6 and push filter onto each cover 2 Install new gaskets 3 on each cover 2 and align bolt holes in gasket with holes in cover For all transmissions 1 Install filter cover assemblies into the filter compartments Align each filter cover assembly with the holes in the botto
63. m of the control module Push the cover assemblies in by hand to seat the seals 36 CAUTION Do not use the bolts to draw the filter covers to the control module Do not use an impact wrench to tighten the bolts Using an impact wrench to tighten the bolts may cause stripped threads and expensive parts replacement Use a torque wrench to tighten the bolts e Install six bolts into each cover assembly and tighten to 51 61 Nem 38 45 16 ft Replace the drain plug Install the drain plug tighten to 25 32 Nem 18 25 Ib ft c Refill Transmission Refer to Table 2 9 for fluid refill guantities The amount of refill is less than the amount used for the initial fill Fluid remains in the external circuits and transmission cavities after draining the transmission After refill check the fluid level using the procedure described in Section 2 3 TRANSMISSION FLUID TEST Paragraph b Manual Fluid Test Procedure Table 2 9 Transmission Fluid Capacity ImitialFil Refill Mi 122013 Approximate guantities do not include external lines and cooler hose 1 Add 2 8 liters 3 guarts for transmissions with PTO 2 9 FLUID LEAK DIAGNOSIS a Finding the Leak 1 Identify the fluid Determine whether the fluid is e Engine oil e Automatic transmission fluid e Hydraulic fluid from a particular vehicle system 2 Operate the vehicle to reach normal operating temperature and park the v
64. mission and mounting components Fluid leaks repair immediately Loose dirty or improperly adjusted throttle sensor Damaged or loose hoses e Worn frayed or improperly routed electrical harnesses Worn or frayed electrical connections Dented worn or out of phase driveline U joints and slip fittings Clogged or dirty breather Inspect the vehicle cooling system occasionally for evidence of transmission fluid Transmission fluid in the vehicle cooling system indicates a faulty oil cooler CAUTION When welding on the vehicle DO NOT WELD on the vehicle without disconnecting all control system wiring harness connectors from the ECU DO NOT WELD the vehicle without disconnecting ECU battery power and ground leads DO NOT WELD any control components DO NOT CONNECT welding cables to any control components A label ST2067EN describing on vehicle welding precautions is available from your authorized Allison service dealer and should be installed in a conspicuous place A vehicle used in a vocation that requires frequent modifications or repairs involving welding must have an on vehicle welding label 2 2 IMPORTANCE OF PROPER TRANSMISSION FLUID LEVEL Transmission fluid cools lubricates and transmits hydraulic power Always maintain proper fluid level If fluid level is too low the torque converter and clutches do not receive an adequate supply of fluid and the transmission overheats 20
65. mm 2 inches equals cable length OPERATING BAND 15 2 22 9 mm 0 6 0 9 in The location of the clamping bracket relative 3 75 in to the fuel lever at closed throttle must be maintained s within this range Attach to engine or governor 30 2 mm 1 19 in housing using clamp and shims as required Clamp must positively 93 45 mm 3 679 in 87 15 mm 3 431 in lock cable groove Fuel lever attachment linkage or bracket must HITCH PIN CLIP allow fuel lever to return to closed throttle position ENGINE FUEL LEVER when sensor rod is maintained at full throttle position Attach the throttle sensor directly to the engine fuel lever with no breakover or yield linkages between the engine fuel lever shaft and the attachment point of the throttle sensor CLOSED THROTTLE 183 1 mm 7 21 in FULL THROTTLE SAME AS WITHOUT e 160 2 mm 6 31 in MIN gt SLIP LINK FULLY EXTENDED EEE CES uL 38 1 mm 1 50 in HITCH PIN CLIP FULLY RETRACTED OPTIONAL THROTTLE SENSOR ASSEMBLY WITH SLIP LINK V00430 06 Figure 5 6 Hitch Pin Throttle Position Sensor Installation Diagram 67 2 3 Secure the sensor body using the mounting holes provided Install a heat shield if any part of the throttle sensor is near the exhaust manifold turbochargers or any other heat source Adjust the throttle sensor as follows 1 2 The
66. ne and fill tube Scale none Dimension determined by installation eference dimension only Actual dimension to be determined by installation R eference drawing AS66 460 eference drawing 5 67 460 VO7301 00 05 Figure 2 2 Standard 3000 And 4000 Product Families Dipstick Markings 26 2 4 KEEPING FLUID CLEAN Prevent foreign material from entering the transmission by using clean containers fillers etc Lay the dipstick in a clean place while filling the transmission CAUTION Containers or fillers that have been used for antifreeze solution or engine coolant must NEVER be used for transmission fluid Antifreeze and coolant solutions contain ethylene glycol which if put into the transmission can cause the clutch plates to fail 2 5 FLUID RECOMMENDATIONS The hydraulic fluid oil used in the transmission directly affects transmission performance reliability and durability Customers may continue to choose from a wide variety of approved DEXRON III or Allison qualified C4 fluids Customers may elect to use TranSynd or TES 295 equivalent and extend drain intervals Equivalent TranSynd fluid must meet or exceed TES 295 specifications TranSynd is a fully synthetic transmission fluid developed by Allison Transmission and Castro Ltd and is fully qualified to the GM TES 295 specifications DEXRON III fluids are also acceptable for off highway applications To be sure a fluid is qualified for
67. nect the tachograph or speedometer cable from the port on the rear of the retarder housing For 3000 Product Family transmissions built beginning in January 1998 disconnect the wiring harness from the retarder temperature thermistor the output speed sensor and the retarder valve body connector If used disconnect the tachograph cable from the port on the rear of the retarder housing refer to Figure 3 2 For the 4000 Product Family transmissions disconnect the retarder connector the retarder temperature sensor connector and if used the tachograph cable refer to Figure 3 1 If a PTO s is used disconnect the PTO s wiring harness UNCOUPLING FROM DRIVELINE ENGINE AND VEHICLE Disconnect the vehicle drive shaft from the transmission output flange or yoke Position the disconnected shaft to avoid interference when removing the transmission If PTO equipped disconnect PTO connections such as PTO hydraulic hoses PTO powered equipment drive shaft If transmission mountings support the rear of the engine place a jack or other support under the engine Securely support the transmission with a hoist jack or other suitable removal equipment Remove all bolts nuts washers spacers and supports that attach the transmission to the vehicle and the engine 52 OUTPUT SPEED SENSOR REAR COOLER PORTS FRONT COOLER OPTIONAL
68. nter pilot boss with molybdenum disulfide grease Molycote G or equivalent 3 Install a headless guide bolt into one of the flexplate bolt holes in the flexplate adapter or torque converter mounting lug refer to Figure 5 3 Align the guide bolt with the flexplate hole at the access opening 4 Push the transmission toward the engine while guiding the pilot boss on the torque converter into the flexplate hub adapter and the guide bolt into the hole on the flexplate 5 Seat the transmission squarely against the engine flywheel housing NO FORCE IS REQUIRED If interference is encountered move the transmission away from the engine and investigate the cause 6 Align the bolt holes in the converter housing with those in the engine flywheel housing 7 Install all transmission to engine bolts finger tight CAUTION The entire converter housing circumference must be flush against the engine flywheel housing before tightening any bolts DO NOT use the bolts to seat the housing 8 Tighten four bolts at equally spaced intervals around the converter housing bolt circle Use the torque specified by the engine or vehicle manufacturer usually M10 x 1 5 6H bolts tightened to 51 61 Nem 69 9 38 45 Ib ft 7 14 bolts tightened to 73 88 Nem 54 65 Ib ft 3 16 bolts tightened to 49 58 Nem 36 43 Ib ft Remove the flexplate guide bolt through the engine fiywheel housing access opening Replace it with a self locking b
69. olt Tighten the bolt finger tight NOTE DO NOT tighten any flexplate to flexplate adapter bolts until all of the bolts have been installed and tightened finger tight 10 Rotate the engine crankshaft to install the remaining self locking bolts into 11 6 3 Install all bolts washers spacer isolators or supports reguired to support 6 4 6 5 the flexplate adapter After all bolts have been installed finger tight tighten 8 bolts to 33 39 Nem 25 29 Ib ft and 10 bolts to 63 73 Nem 46 54 Ib Install the flywheel housing access cover if used INSTALLING TRANSMISSION MOUNTING COMPONENTS CAUTION Use the type and grade of mounting bolts recommended by the vehicle manufacturer the transmission in the vehicle frame Tighten the bolts to the torque values recommended by the vehicle manufacturer COUPLING TO DRIVELINE Couple the driveline companion flange or universal joint yoke to the flange or yoke on the transmission Use the bolts and torque values recommended by the vehicle manufacturer Determine the universal joint angularity of all U joints in the driveline Confirm that they are within specification CONNECTING OUTPUT RETARDER ACCUMULATOR The output retarder is connected to the vehicle air system by an air supply line attached to the retarder control solenoid mounted on the end of the retarder accumulator refer to Figure 6 1 70 RETARDER SYSTEM SCHEMATI
70. oubleshooting information that best applies to the situation e Use the transmission s individual clutch apply circuit pressure taps when necessary f Troubleshooting Intermittent Diagnostic Codes Intermittent codes are a result of conditions which are not always present 43 a HOLD OVERRIDE BUTTON MODE INDICATOR MODE BUTTON MODE ID t 1 DIAGNOSTIC BUTTON SIX SPEED LEFT HAND SIX SPEED RIGHT HAND LEVER SELECTOR LEVER SELECTOR DIGITAL DISPLAY MODE 10 m L ntm LED 2 nel simultaneously 3 to enter diagnostic mode and fluid level 218 check optional PUSHBUTTON STRIP PUSHBUTTON SELECTOR SHIFT SELECTORS NOTE Number displayed is highest forward range available in selected position Visually check to confirm range selected If display is flashing shift is inhibited Figure 2 4 Typical Shift Selectors When conditions causing the code exist the code is logged in memory The code stays in memory until it is manually cleared cycled out When intermittently occurring codes exist inspect test and correct the following items Dirty damaged or corroded harness connectors and terminals Terminals not fully seated in connectors Damaged h
71. outine 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 0 rpm such as at a stop This parameter should be set to a higher value than the expected transmission stall speed before performing the stall test b Stall Testing Preparation If a transmission stall test is to be performed make sure the following preparations have been made before conducting the transmission stall test 45 The manufacturer concurs with performing full throttle transmission stall test The engine programmable parameter for 0 rpm transmission output speed is set higher than the value expected at transmission stall speed The vehicle is in an area in which a transmission stall test can be safely performed Make sure the fuel control linkage goes to full throttle and does not stick when released Make sure the engine air induction system and exhaust system have no restrictions 6 Determine the cold t
72. r electrical connections frayed insulation wiring damage e Fluid pressure gauge tubing damage kinks improper routing 65 Adjust so total stroke is within 0 COUNT 50 200 count band 255 COUNTS 14 COUNTS 233 COUNTS 150 COUNTS 200 COUNTS ERROR ZONE ERROR ZONE 19 0 75 in STROKE CLOSED THROTTLE WIDE OPEN THROTTLE FULLY FULLY AT REST Total Stroke CT WOT os 0 1 in 15 2 mm 22 9 mm vu 0 0 6 0 9 in 2 85 130 Counts pa 00429 05 Figure 5 5 Throttle Position Determination Diagram b Throttle Position Sensor TPS Adjustment Using Diagnostic Tool When properly installed by the eguipment manufacturer the TPS should not need adjustment If TPS adjustment is necessary confirm that it has been installed to Allison Transmission specification refer to Figure 5 5 The TPS 18 self calibrating and therefore has no optimum closed throttle or full throttle count value Idle count should be 50 or higher and full throttle count 200 or lower As long as the counts are in the 50 and 200 count range with a difference of 85 to 130 counts between closed and full throttle the TPS is set correctly Error codes occur if the idle position is less than 14 counts or when the full throttle position is more than 233 counts The Allison DOC For 5 Tool read TPS counts Watch the TPS movements as the controls
73. ransmission fluid level and adjust as necessary 7 Connect Allison DOC For PC Service Tool to the vehicle diagnostic 9 data connector or install accurate tachometer do not rely the vehicle tachometer Install a temperature gauge with the probe in the transmission converter out to cooler line Allison DOC M displays sump temperature only Install wheel chocks 10 A driver is in the driver s position 11 The vehicles brakes are fully locked WARNING help avoid personal injury such as burns from hot transmission fluid and or to help avoid equipment damage do not stall the torque converter for more than ten seconds maximum and monitor transmission fluid temperature Immediately return the engine to idle if converter out to cooler temperature exceeds 150 C 300 F Operating the transmission at high engine power at transmission stall or near stall conditions causes a rapid rise in the transmission fluid temperature The fluid in the transmission torque converter is absorbing all of the engine power and the vehicle cooling system cannot dissipate the excessive heat load Extended operation under high heat load conditions causes transmission and cooling system damage and can possibly fail hydraulic lines causing high temperature fluid WARNING To help avoid personal injury and equipment damage while conducting a transmission stall test the vehicle must be positively prevented from moving Apply the par
74. se for concern should only when significant deviations in the established trendline are present While trendline analysis on wear metals can prove informative and useful a transmission removal decision should not be based solely upon the analysis A removal based solely on wear metal analysis may result in an unnecessary tear down The results should be used in conjunction with other inspection procedures such as functional check road test or fluid sump internal filter inspection Transmission removal should occur only if the additional investigation warrants it c Water Engine Coolant Contaminant NOTE Cooler water can be contaminated by engine oil Be sure to J locate the actual source of cooler contamination The presence of water and or ethylene glycol coolant mixture in the transmission fluid is detrimental to the reliability and durability of the internal components because it has a deteriorating effect on the transmission components Frictional capacity of drive clutch plates can be greatly reduced as a result of surface film or impregnation and the presence of glycol will physically deteriorate clutch plate materials If contamination is suspected obtain a fluid sample when transmission fluid is at normal operating temperature to be sure a contaminant if present is thoroughly dispersed in the fluid being sampled The analysis of the sample by the fluid supplier or any qualified laboratory will provide the degree o
75. st have a positive main pressure shut off at the solenoid valve when the PTO is not engaged Failure to provide this feature may cause inadvertent clutch apply and PTO damage CAUTION PTO units using transmission main pressure to engage the 4 Couple the PTO output to its driven eguipment Inspect couplings or universal joints for correct assembly and alignment If the driven component is not a direct mount arrangement inspect the PTO drivelines for angularity phasing and offsets 6 7 CONNECTING PARKING BRAKE CONTROL 1 Connect and properly adjust the parking brake 2 If present adjust the brake shoe to drum clearance as specified by the manufacturer This does not apply to 4000 Product Family 6 8 CONNECTING COOLER Refer to Figure 6 2 for typical cooler port locations on the transmission and recommended torque for cooler line fittings 6 9 CONNECTING ELECTRICAL COMPONENTS NOTE Allison Transmission electronic control systems are designed and manufactured to comply with all FCC and other guidelines regarding radio frequency interference electromagnetic interference RFI EMI for transportation electronics Manufacturers assemblers and installers of radio telephone or other two way communication radios have the sole responsibility to correctly install and integrate those devices into Allison Transmission equipped vehicles to customer satisfaction For further information refer to TS2973EN the WTEC III Electronic
76. termine the length of the stall condition If the stall test is repeated do not let the engine overheat 8 Record converter out to cooler temperature 9 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 12 Proceed to the Paragraph g Neutral Cool Down Check Procedure 47 4 Driving Transmission Stall Test NOTE If the vehicle is eguipped with a smoke controlled or an J emission controlled engine or engine control programming inhibiting engine acceleration the following stall test procedure can be used WARNING To help avoid personal injury and or equipment damage a driving transmission stall test must be performed by a trained driver and a qualified technician e Driving Transmission Stall Test Preparation If a driving transmission stall test is to be performed make sure the following preparations have been made before conducting the test 1 The manufacturer concurs with performing a full throttle transmission stall test 2 The engine programmable parameter for 0 rpm transmission output speed is set higher than the value expected at transmission stall speed 3 The vehicle is in an area in which the transmission stall test can be safely performed 4 Make sure the fuel control linkage goes to full throttle and does not s
77. the retarder valve body connector Also the tachograph cable if used to the port on the rear of the retarder housing 3 If used connect the PTO s connector s The PTO connector is not part of the Allison Transmission external wiring harness 4 Be sure the speed sensors the PTO connector and other connections are securely seated and latched by pulling on the connector NOT THE WIRES On the 3000 Product Family turn the retarder connector if used until feeling a positive snap on the connector 5 The transmission has a sump fluid temperature sensor on the internal wiring harness A retarder fluid temperature sensor is installed in the retarder on retarder equipped models Actual temperature reading can be made with diagnostic tool Hot fluid conditions in the sump or retarder are read through the diagnostic tool by programming an output function 6 A temperature gauge may be installed in the To Cooler line No temperature gauge installations are available on integral cooler installations If equipped for them install a temperature probe capillary tube and bulb or thermocouple 7 If equipped with a capillary tube and bulb a Tightened the adapter tight enough to prevent leakage b Install the bulb into the adapter and tighten the nut c Inspect the capillary tube for interference with other parts that might chafe or damage the tube 8 If equipped with a thermocouple a Long tubes may require support clips or brack
78. tick when released 5 Inspect the engine air induction system and exhaust system to make sure there are no restrictions 6 Determine the cold transmission fluid level and adjust as necessary 7 Connect the Allison DOC service tool to the vehicle diagnostic data connector 8 Install an accurate tachometer do not rely on the vehicle tachometer 9 Install a temperature gauge with the probe in the transmission converter out to cooler hose Allison DOC displays sump temperature only 48 f Performing Driving Transmission Stall Test CAUTION The transmission stall test procedure causes a rapid rise in transmission fluid temperature that can damage the transmission Never maintain a stall condition once engine speed stabilizes or converter out to cooler temperature exceeds 150 C 300 F During a stall condition converter out temperature rises much faster than the internal sump temperature Never use sump fluid temperature to determine the length of the stall condition If the stall test is repeated do not let the engine overheat 1 Start the engine While in neutral let the transmission warm to normal operating temperature e Sump temperature 71 93 160 2009F e Converter out temperature 82 104 C 180 2209 Determine the hot transmission fluid level and adjust as necessary Turn OFF all engine accessories While located in an isolated area begin the driving transmission stall test
79. ts CHECK TRANS light and shift selector display Transmission fluid pressure gauge if used Speedometer Temperature gauge if used Reverse warning system if used Transmission Fluid Fluid level meets specifications cold neutral level No leaks No Load Governed Engine Speed No load governed speed of engine Adjust governor as necessary refer to the manufacturer s specifications for the engine transmission being tested Output Retarder Operation of the output retarder if installed while descending a grade or slowing on a level road if installed PTO operation Refer to the appropriate Operator s Manual Refer to the Customer Service section Table 8 1 for the current publication number Shift Sequence Transmission upshifts and downshifts smoothly through all ranges Other Tests Stall test Shift quality Comments 79 Section VIII CUSTOMER SERVICE 8 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 8 2 SERVICE LITERATURE Additional servic

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