- Allison Transmissions
Contents
1. Installing Scavenge Pump InstallingFillTubeAndSeal Checking Plugs And Openings PREPARING VEHICLE FOR TRANSMISSION INSTALLATION Engine Transmission Adaptation Requirements Checking Flexplate Drive Assembly Chassis And Driveline Inspection iii Page 20 20 22 22 22 23 23 24 24 25 25 26 28 29 Paragraph 4 4 4 5 SECTION V SECTION VI 6 1 6 2 SECTION VII 7 1 7 2 Description Page Cooler Filter Andlines 30 CheckingControls 31 INSTALLING TRANSMISSION INTO VEHICLE Handling 5i u pawa 35 MountinggToEngine 35 Installing Transmission Mounting Components 36 CouplingToDriveline 36 ConnectingPowerTakeoffControls 36 ConnectinggCooler 37 ConnectingSpeedometerDrive 37 ConnectingElectricaaComponents 38 FillingHydraulicSystem 39 MnstallattonChecklist 39 CHECKS AND ADJUSTMENTS MnstallattonChecklist 40 Road Test And Vehicle OperationChecklist 42 CUSTOM ER SERVICE OwnerAssistance 44 Service Literature sss so d REC dns 44 P2. Hydraulic lines Check for contamination clean and flush as necessary Inspect for deterioration Inspect for faulty connectors or kinks b After Overhaul A complete cleanup of the transmission system after an over haul cannot be assumed Repeated cleaning and flushing may not remove all debris from the transmission fluid cooler system Replace the transmission from cooler lube filter after 8000 km 5000 miles Refill the transmission to the correct fluid level refer to Paragraph 1 3 30 4 5 CHECKING CONTROLS a Inspection Inspect the following and correct any faulty conditions Shift selector improper operation poor electrical connection improper harness routing Cab and chassis wiring harness poor connections frayed insulation wiring damage Throttle sensor components freedom of movement improper routing bellows damage improper or loose cable mounting PTO controls damage wear improper operation lubrication Scavenge pump damage wear improper operation lubrication Temperature gauge capillary tube damage if used sensor damage Fluid pressure gauge tubing damage kinks improper routing 31 b Throttle Position Sensor TPS Adjustment Using Diagnostic Tool When properly installed by the equipment manufacturer the TPS should not need adjustment If TPS adjustment is
3. J Environmental conditions such as ambient temperature altitude engine accessory loss variations etc affect the power input to the converter Under such conditions stall speed can vary from specifica tion by 150 rpm and still be accepted as within normal range If engine stall speed is more than 150 rpm below the stall speed specified by the engine manufacturer an engine problem is indicated If engine stall speed is more than 150 rpm above specification a transmission problem is indicated such as slipping clutches cavitation aeration or torque converter failure An extremely low stall speed such as 33 percent of the specified engine stall rpm during which the engine does not smoke could indicate a freewheeling stator in the converter Perform a neutral cool down check if engine stall speed tests meet specifica tions but cause the transmission fluid to overheat If the engine stall speed meets the specification and the cool down check shows that transmission fluid cools properly an electronic control problem may exist Refer to the latest version of WT Troubleshooting Manual TS2470EN d Neutral Cool Down Check Procedure The neutral cool down check determines if the transmission fluid cools following an engine load condition Perform this check immediately after the maximum engine rpm has been recorded in the stall test Record the converter out fluid temperature Reduce the engine rpm to idle and shift to N Neut
4. 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 26 LC uoneidepy 1d0Z0 GIN L 4 MOUNTING FACE OF ENGINE 2 J lt 50 38 mm 1 08 mm 1 993 in 0 043 in FLYWHEEL HOUSING Design shall result in the flexplate outside diameter being deflected 0 38 mm 0 0151 in away from engine See VIEW B for flexplate adapter design position MB X 1 25 X VARIOUS LENGTHS 12 WASHER HARDENED STEEL FLYWHEEL HOUSING SAE STANDARD J617 2 32 63 mm 1 285 in TORQUE 49 58 Nem 36 43 LB FT FOR X 1 5 6H BOLT TORQUE TO 24 29 Nem 17 21 LB FT TORQUE TO 51 61 Nem 38 4518 10 BOLT 1995 MODEL 1 MBX 1 25 X 25 0 mm 0 98 in TORQUE TO 24 29 17 21 LB FT lt e gt 50 76 mm 1 998 in Design shall result in the flexplate outside diameter being deflected 0 38 mm 0 0151 in away from engine See VIEW A for converter position 1450 mm 571 MN ENGINE CRANKSHAFT CENTERLINE TRANSMISSION CONVERTER SPACE CLAIM torque requirements VIEWB ENGINE ADAPTATION REQUIREMENTS
5. Allison Iransmission Mechanic s Tips MD 3070PT Series Transmissions MT2923EN MT2923EN Mechanic s Tips Allison Transmission MD 3070PT e Allison February 1995 Transmission Rev 1 June 2000 Allison Transmission Inc P O Box 894 Indianapolis Indiana 46206 0894 www allisontransmission com Printed in U S A Copyright O 2007 Allison Transmission Inc IMPORTANT SAFETY NOTICE IT IS YOUR RESPONSIBILITY to be completely familiar with the warnings and cautions used in this manual These warnings and cautions advise against using specific service procedures that can result in personal injury damage to the equipment or cause the equipment to become unsafe These warnings and cautions are not exhaustive Allison Transmission could not possibly know evaluate or advise the service trade of all conceivable procedures by which service might be performed or of the possible hazardous consequences of each procedure Consequently Allison Transmission has not undertaken any such broad evaluation Accordingly ANYONE WHO USES A SERVICE PROCEDURE OR TOOL WHICH IS NOT RECOMMENDED BY ALLISON TRANSMISSION MUST first be thoroughly satisfied that neither personal safety nor equip ment safety will be jeopardized by the service procedures used Proper service and repair are important to the safe and reliable operation of the equipment The service procedures recom mended by Allison Transmission and described in this manu
6. powder surface to the source A c Black Light and Dye Method Pour the specified amount of dye into the transmission fill tube NOTE A dye and black light kit is available for finding leaks Refer to the manufacturer s directions when using the kits See kit directions for the color of the fluid and dye mix Operate the vehicle in normal operating conditions Direct the black light toward the suspected area The dyed fluid will appear as a brightly colored path leading to the source 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 dirty damaged threads Warped flanges or sealing surfaces Scratches burrs or other damage to a sealing surface Damaged or worn out gasket Cracked or porous casting Improper sealant used where applicable Seals Fluid level pressure is too high Plugged vent or drain back holes Damaged seal bore Damaged or worn out seal Improper installation Cracks in component Output shaft surface scratched nicked or damaged Loose or worn out bearing causing excess seal wear Sealing Flange Inspect the sealing flange for bends replace the sealing flange if bent 1 10 BREATHER a Location and Purpose The breather is located on top of the transmission con verter ho
7. 0 250 in A BOTTOM FILL TUBE 1 101 6 4 00 in 86 6 mm 63 5 mm 3 41 in 2 50 in 45 7 mm 1 80 in Y Y 5 9 mm 0 23 in SPLIT LINE TO BE DETERMINED BY Calibration level marking INSTALLATION locations with respect to transmission control module split line and fill tube SCALE NONE 01727 Figure 1 1 3070PT Dipstick Markings 5 e Consistency of Readings Always check the fluid level at least twice and with the engine running Consistency is important to maintaining accuracy of the reading If inconsistent readings persist check the transmission breather to be sure it is clean and unclogged 1 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 1 5 FLUID RECOMMENDATIONS Hydraulic fluid oils used in the transmission are important influences on transmission performance reliability and durability DEXRONS III fluid is recommended for on highway applications Type C 4 fluids are recommended for severe duty and off highway applications DEXRON III fluid is also qualifi
8. All control module bolts 51 61 N m 38 44 Ib ft Breather 12 16 N m 9 12 lb ft Control module pressure taps 10 13 N m 7 10 Ib ft Cooler fittings 12 34 47 N m 25 35 lb ft 16 54 68 N m 40 50 Ib ft 20 68 81 N m 50 60 Ib ft Cooler port cover bolts 51 61 N m 38 44 Ib ft Expansion plug 1 2 N m 9 18 Ib in External harness to transmission connector bolt 1 2 N m 9 18 Ib in Flexplate adapter to converter cover bolts 24 29 N m 18 21 Ib ft Flexplate to crankshaft hub bolts Consult Engine Manufacturer Specifications Flexplate to flexplate adapter bolts 12 bolt design 24 29 N m 18 21 Ib ft 6 bolt design 51 61 N m 38 44 Ib ft Fluid drain plug 25 32 N m 18 24 Ib ft Fluid fill tube bracket 24 29 N m 18 21 Ib ft Speed sensor bolts 24 29 N m 18 21 Ib ft Output flange bolts 30 35 N m 22 26 lb ft PTO cover bolts 51 61 N m 38 44 Ib ft PTO mounting bolts 51 61 N m 38 44 Ib ft PTO pressure hose to transmission 10 13 N m 7 10 Ib ft 40 L Rear cover bolts 90 110 N m 66 81 Ib ft L TPS to transmission bracket 108 122 N m 80 90 Ib ft L Transmission electronic connector bolts 5 7 N m 48 62 lb in Cooler Fluid Lines and Air Hose for L No leaks Connection tightness Correct routing Throttle Sensor for Proper adjustment L Correct routing of cable and harness Driveline for
9. Proper indexing of universal joints Proper drive shaft angles Driveline backlash Lubricated universals and slip joints Hydraulic System for Recommended fluid or C 4 fluid Correct fluid level in transmission Dipstick correctly calibrated Fill tube tight Fill tube cap tight Breather clean and free of restrictions No fluid leaks during operation Instruments and Electrical Equipment for L Proper wiring and electrical connections Instruments gauges and lights work correctly L Shift selector display is on and DO NOT SHIFT light is off L Fluid temperature gauge Power Takeoff for LI Controls connected and operative Correctly coupled to driven equipment Lubrication line correctly installed and routed if used 41 6 2 ROAD TEST AND VEHICLE OPERATION CHECKLIST NOTE J Refer to MD 3070PT Transmission Operator s Handbook for operating instructions a Driveability Drive away checks are performed to verify proper transmission and support equipment installation and operation The following steps outline drive away check procedures Check Fluid fill the transmission with the appropriate fluid q S Start the Vehicle check for proper system response during start up Z Turn on the vehicle s master ignition switch The DO NOT SHIFT light should come on Start the engine The DO NOT SHIF
10. and filter change frequency is determined by the severity of transmission service and the filter equipment installed Table 1 2 is a general guide More frequent changes may be necessary when operating conditions create high levels of contamination or overheating Table 1 2 Transmission Fluid and Filter Change Table Transmission Fluid and Filter Change Interval MD3070PT On highway After the first 8000 km 5000 miles thereafter 40 000 km 25 000 miles or 18 months MD3070PT Off highway After first 500 hours thereafter 1000 hours max or 18 months Whichever comes first b Abnormal Conditions Transmission fluid must be changed whenever there is evidence of dirt or a high temperature condition A high temperature condition is in dicated by the transmission fluid being discolored or having a strong odor or by fluid analysis Local conditions severity of operation or duty cycle may require more or less frequent fluid or filter change intervals c Fluid Analysis Transmission protection and fluid change intervals can be opti mized by monitoring fluid oxidation according to the tests and limits shown in Table 1 3 Consult your local telephone directory for fluid analysis firms To ensure con sistent and accurate fluid analysis use only one fluid analysis firm Refer to the Technician s Guide for Automatic Transmission Fluid SA2055 for additional infor mation Table 1 3 Fluid Oxidation Meas
11. for loose bolts transmission and mounting components fluid leaks repair immediately loose dirty or improperly adjusted throttle sensor linkage damaged or loose hoses worn frayed or improperly routed electrical harnesses worn or out of phase driveline U joints and slip fittings CAUTION When welding on the vehicle DO NOT WELD on the vehicle without disconnecting from the ECU all control system wiring harness connectors DO NOT WELD on the vehicle without disconnecting ECU battery power and ground leads DO NOT WELD on any control components DO NOT CONNECT welding cables to any control components A label describing on vehicle welding precautions is available from your authorized Allison service dealer and should be installed in a conspicuous place A vehicle used in a vocation that requires frequent modifications or repairs involving welding must have an on vehicle welding label 1 2 IMPORTANCE OF PROPER TRANSMISSION FLUID LEVEL Transmission fluid cools lubricates and transmits hydraulic power Always maintain proper fluid level If fluid level is too low the torque converter and clutches do not receive an adequate supply of fluid and the transmission overheats If the level is too high the fluid aerates causing the transmission to shift erratically and overheat Fluid may be expelled through the breather or dipstick tube when the fluid level is too high 1 TRANSMISSION FLU
12. 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 2 4 REMOVING THE TRANSMISSION 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 Raise or lower the transmission as necessary to remove it from the vehicle 2 5 REMOVING OUTPUT FLANGES OR YOKES MD 3070PT outputs use two large self locking nuts A special procedure must be followed for removal and installation of the nut CAUTION The use of an impact wrench on the MD 3070PT output nut requires a means to hold the flange Failure to hold the flange can cause internal damage to the transmission Remove dirt and burrs from the shaft threads Then loosen the nut until there is about 1 46 inch gap between the nut and flange Check the running torque as the nut is being removed The running torque must be at least 19 5 N m 14 Ib ft Discard the nut if it does not meet the running torque limit 22 SECTION PREPARING THE III TRANSMISSION FOR INSTALLATION 3 1 CHECKING INPUT COMPONENTS a Bolt Holes Check all bolt holes on the front of the flywheel converter cover flexplate adapter The threads must be undamaged and the holes free of chips or foreign material b Pilot Boss Check the pilot b
13. low voltage Example Code 21 12 21 indicates a problem with throttle position sensor signal 12 indicates the throttle position sensor signal was low If the condition causing the diagnostic code still exists it s identified by YES in the Active Indicator area If the condition causing the diagnostic code is no longer present it s identified by NO in the Active Indicator area When using the shift selector to retrieve trouble codes the illumination of the MODE ON indicator on the shift selector indicates that the code displayed is currently active If the MODE ON indicator is not illuminated with the displayed code the code is inactive In the normal operating mode the MODE ON display indicates secondary mode operation 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 counter reaches 25 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 D1 the active indicator is turned on and the Ignition Cycle Counter is cleared and 1 is added to the Event Counter Youcan access the ignition cycle counter and event counter information through Pro Link diagnostic tool only c Clearing The Trouble
14. 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 FULL THROTTLE 183 1 mm 7 21 MAX SAME AS WITHOUT SLIP LINK 4 160 2 mm 6 31 gt FULLY URS GECE M 38 1 mm 1 50 E d HITCH PIN CLIP FULLY RETRACTED OPTIONAL THROTTLE SENSOR ASSEMBLY WITH SLIP LINK V00430 01 Figure 4 5 Hitch Pin Throttle Position Sensor Installation Diagram 33 c Hitch Pin Throttle Position Sensor Installation Install the throttle sensor body as follows Clamp cable end using clamp and shims refer to Figure 4 5 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 The engine fuel lever must be at the closed throttle position Install the hitch pin cable end of the 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 22 9 mm 0 60 0 90 inch from the idle position Check the stroke distance of the throttle sensor from closed to wide open Stroke distance must be from 15 22 9 mm 0 60 0 90 inch Rech
15. the position it was in when the light came on initially Ifignition is turned OFF and then ON while the DO NOT SHIFT light is displayed the transmission will remain in neutral until the code is cleared Any time the DO NOT SHIFT light is displayed the ECU logs a diagnostic code in memory These diagnostic codes can be accessed through the shifter display or a diagnostic tool NOTE J Diagnostic codes can be logged without illuminating the DO NOT SHIFT light This occurs when the ECU senses a problem but determines the problem won t cause immediate transmission damage or dangerous performance b Diagnostic Codes Overview Table 1 5 Diagnostic Codes Overview Ignition Code List Main Code Sub Code Active Cycle Event Position Indicator Counter Counter Displayed on shift selector YES MODE Accessible by Pro Link ON Displayed diagnostic tool only Diagnostic codes are listed in memory Up to five codes can be stored with the most recent code listed first Diagnostic codes consist of a two digit main code and a two digit sub code Main codes are listed first and provide the general condition or area of fault detected by the ECU Sub codes are listed second and provide specific areas or conditions within the main code that caused the occurrence Example Code 13 12 13 indicates a problem with ECU voltage 12 indicates the problem was caused by
16. the WT 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 When conditions causing the code exist the code is logged in memory The code stays in memory until it s manually cleared or cycled out 16 When intermittently occurring codes exist check for the following items Dirty damaged harness connectors and terminals Terminals not fully seated in connectors Damaged harnesses 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 To help locate intermittents it sometimes helps to place the appropriate tester on the suspect component or circuit and simulate operating conditions wiggle pull bump and bend while watching the tester g Exiting The Diagnostic Mode 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 t Up and Y Down arrow buttons Using a pushbutton shift selector press D Drive N Neutral or R Reverse Using a lever shift selector press the DISPLAY MODE button Using a lever shift selector move the shift selector to any position other than the one it was in when t
17. 01719 01 V01717 Figure 4 2 Converter Axial Location Measurement h Flexplate Bolt Hole Flatness Flexplate flatness in the area of the bolt holes is not a measurement required for the MD 3070PT transmission i Torque Converter Axial Location Refer to Figure 4 2 Using depth gauge measure from the torque converter housing to the torque converter s flexplate adapt er mounting face The torque converter axial location should measure 50 76 mm 1 998 inch 4 2 CHECKING FLEXPLATE DRIVE ASSEMBLY a Flexplate Inspection Check the flexplate for cracks distortion or elongated bolt holes Replace a worn or damaged flexplate b Engine Crankshaft End Play Ensure engine crankshaft end play is within the engine manufacturer s specifications CRANKSHAFT HUB ADAPTER STARTER RING GEAR WEARPLATE ENGINE FLYWHEEL HOUSING FLEXPLATE ASSEMBLY FLEXPLATE ADAPTER V00533 03 Figure 4 3 Arrangement of Adaptation Components NOTE J When assembling the flexplate to the crankshaft hub or hub adapter ensure the outer flexplate bolt holes are aligned c Flexplate Assembly Installation Install the flexplate onto the engine crankshaft hub using the bolts and torque values specified for that engine Refer to Figure 4 1 for the proper position of an installed flexplate 4 3 CHASSIS AND DRIVELINE INSPECTION Inspect the chassis and driveline components
18. Codes Using Shift Selector During installation false codes can be recorded in the electronic control s memory You must clear these codes prior to road testing the vehicle Use the shift selector to clear the codes Refer to Figure 1 3 Enter the diagnostic mode on pushbutton selectors by pressing the T Up and 4 Down arrow buttons simultaneously Press twice if there is an oil level sensor present Enter the diagnostic mode on lever selectors by momentarily pressing the DISPLAY button Press twice if there is an oil level sensor present e To clear all active indicators press and hold the MODE button approximately 3 seconds until a tone sounds To remove all codes press and hold the MODE button for approximately 10 seconds until the shift selector tone sounds twice d Retrieving Troubleshooting Codes During installation false diagnostic codes can be recorded in the electronic control s memory Clear these codes before road testing the vehicle After road testing the vehicle check for the codes Retrieve the codes by using the shift selector Refer to Figure 1 3 Enter diagnostic mode The display will list the code s logged position d1 d2 d3 etc then follow with the main code and a sub code this repeats every 2 seconds until the MODE button is pushed again Momentarily push the MODE button to move to the next code stored in memory When you have retrieved all the codes the display will
19. ID CHECK a Electronic Fluid Check Procedure If the transmission you are maintaining has an oil level sensor fluid level information can be dis played on the shift selector If the transmission does not have an oil level sensor refer to Paragraph 1 3 Step b Manual Fluid Check Procedure Displaying Fluid Level Information Use the following procedure to display fluid level information For a pushbutton shift selector Simultaneously press the T Up and di Down arrow buttons For a lever shift selector Press the MODE button Oil Fluid Level Mode A two minute countdown begins after entering oil level mode The display flashes and an 8 7 1 count occurs during the two minute countdown Oil level information displays after the countdown and when the following conditions are met Engine at idle Sump oil at operating temperature Transmission output shaft stopped Transmission in neutral Oll level sensor functioning properly Shift Selector Display After two minutes the shift selector will display the fluid level data as in the following examples CODE MEANING OF CODE OL OK OK Oil level is correct OL LO 01 Oil level is one quart low or as many quarts as needed OL HI 01 Oil level is one quart high or as many quarts as overfilled The shift selector can only display two characters at a time One character is displayed under the MONITOR label and one under
20. L Fluid level meet specifications cold neutral level No leaks s Warm up and check fluid level hot neutral level No Load Governed Engine Speed No load governed speed of engine Adjust governor as necessary refer to the manufacturer s specifications for the engine transmission being tested PTO PTO operation refer to MD 3070PT Operator s Manual or to the vehicle manufacturer s specific instructions Shift Sequence L Transmission upshifts and downshifts smoothly through all ranges Other Checks Stall test Shift quality Comments 43 SECTION VII CUSTOMER SERVICE 7 1 OWNER ASSISTANCE There are distributors and dealers around the world ready to stand behind every Allison Transmission product Any situation that arises in connection with the sale operation or service of your transmission will be handled by the distributor or dealer in your area Refer to the North American Parts and Service Directory SA2229 or the International Parts and Service Directory SA2338 for a current listing of Allison Transmission authorized distributors and service dealers 7 2 SERVICE LITERATURE This service literature provides fully illustrated instructions for operation maintenance service overhaul and parts support for your transmission To ensure maximum performance and service life from your unit see your dealer or distributor for the following publications Check
21. REFACE This handbook is a mechanic s reference for removing installing or maintaining an MD 3070PT Automatic Transmission All features of the transmission and the vehi cle involved in installation procedures are discussed The information presented will help the mechanic remove install and maintain the transmission in a manner that assures satisfactory operation and long service life For additional detailed informa tion refer to the appropriate transmission service manual and electronic controls troubleshooting manual TRADEMARKS USED DEXRONSG is a registered trademark of General Motors Corporation Pro Link is a registered trademark of Microprocessor Systems Inc IA MD 3070PT SEVEN SPEED WITH TRANSFER CASE CLOSE RATIO POWER TAKEOFF HO1708 o ee ae ro e ie Dar TE Ta MD 3070PT TRANSMISSION LEFT REAR VIEW E01707 02 MD 3070PT TRANSMISSION BOTTOM VIEW V01725 MD 3070PT TRANSFER CASE FRONT VIEW T CASE CONNECTOR V01726 viii PREVENTIVE SECTION MAINTENANCE I 1 1 PERIODIC INSPECTION AND CARE Clean and inspect the exterior of the transmission at regular intervals Severity of service and operating conditions determine the frequency of these inspections Inspect the transmission
22. T light should go off NN should appear on the shift selector display Clear Trouble Codes during installation it s common for false codes to be stored in the electronic control s ECU These codes must be cleared prior to road testing the vehicle Road Test the Vehicle allow the electronic control time to converge shifts Check for Proper Operation check all components for proper mounting and operation and check for transmission fluid leaks at gasket surfaces lines and hoses Re check for Trouble Codes use the Pro Link or shift selector to determine if codes were set during the road test Troubleshoot if codes exist after the road test problems must be found and corrected Refer to WT Troubleshooting Manual TS2470EN b Service and Maintenance Refer to a current issue of the MD Series Service Manual for detailed transmission service and maintenance instructions Refer to a current issue of the MD Series Troubleshooting Manual for detailed electronic con trol system troubleshooting Refer to Section 7 2 for the latest publication number c Road Test Checklist Complete the following check list Neutral Start Circuit Starts only in neutral 42 Instruments DO NOT SHIFT light and shift selector display Transmission fluid pressure gauge if used Speedometer Temperature gauge if used Reverse warning system if used Transmission Fluid
23. al are effective methods for performing service operations Some service procedures require using tools specially designed for the procedure Use special tools when and as recommended Paragraph SECTION I SS ee ON UM Ig SECTION II 2 1 2 2 2 3 2 4 2 5 SECTION III SECTION IV 4 1 4 2 4 3 TABLE OF CONTENTS Description PREVENTIVE MAINTENANCE Periodic Inspection And Care Importance Of Proper Transmission Fluid Level TransmissionFluidCheck KeepingFluidClean FluidRecommendations Transmission Fluid And Filter Change Mmtervals Transmission Fluid Contamination Transmission Fluid And Filter Change Procedure FludleakDiagnosis Breather ka e P EP NC n UE Troubleshooting Transmission Stall Test And Neutral Cool Down REMOVING TRANSMISSION DrainingTransmission DisconnectinggControls Uncoupling From Driveline Engine And Vehicle RemovingTheTransmission RemovingOutputFlangesOrYokes PREPARING THE TRANSMISSION FOR INSTALLATION CheckinginputComponents InstallingOutputFlangeOrYoke MnstalingPTO
24. assembly with the holes in the channel plate sump Push the cover assemblies in by hand to seat the seals Install six bolts into each cover and tighten to 51 61 N m 38 44 Ib ft Replace drain plug O rings Install the plugs and tighten to 25 32 N m 18 24 Ib ft FILTER O RING SQUARE CUT SEAL COVER BOLT V01728 Figure 1 2 Location of Filters for Service c Refill Transmission The amount of refill fluid is less than the amount used for the initial fill Fluid remains in the external circuits and transmission cavities after draining the transmission After refill check the fluid level using the procedure described in Paragraph 1 3 Table 1 4 Transmission Fluid Capacity Initial Fill Refill Transmission Oil Sump PTO Liters Quarts Liters Quarts Type Description MD 3070PT standard yes 37 39 30 32 7 00 in Approximate quantity does not include external lines and cooler hose 1 9 FLUID LEAK DIAGNOSIS a Finding the Leak 1 Identify the fluid Determine whether it is engine oil automatic transmission fluid or hydraulic fluid from a specific vehicle system 10 2 Operate the vehicle to reach normal operating temperature and park the vehicle Inspect the vehicle to identify the source of the leak Refer to the following list for possible points of fluid leaks and their causes Transmission mating surface
25. be before removing the dipstick Do not allow dirt or foreign matter to enter the transmission Dirt or foreign matter in the hydraulic system may cause undue wear of transmission parts make valves stick and clog passages Check the fluid level us ing the following procedure and record the level in your maintenance log WARNING When checking the fluid level be sure the transmission is in N Neutral the parking brake and or emergency brake is set properly and the wheels are chocked Unexpected and possible sudden vehicle movement may occur if these precautions are not taken c Cold Check Procedure The purpose of the cold check is to determine if the transmission has enough fluid to be operated safely until a hot check can be made CAUTION The fluid level rises as fluid temperature increases DO NOT fill above the COLD RUN band if the transmission fluid is below normal operating temperatures Park the vehicle on a level surface Apply the parking brake and chock the wheels Runthe engine for at least one minute Shift to D Drive then to N Neutral and then shift to R Reverse to fill the hydraulic system Finally shift to N Neutral and allow the engine to idle 500 800 rpm With the engine running remove the dipstick from the tube and wipe clean Insert the dipstick into the tube and remove Check the fluid level reading Repeat the check procedure to verify the reading Ifthe fluid level is wi
26. eck for zero clearance at the fuel lever Make sure that the 15 22 9 mm 0 00 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 34 INSTALLING SECTION TRANSMISSION V INTO VEHICLE 5 1 HANDLING a Preventing Damage Carefully handle the transmission to prevent damage to components in the installation path b Control of Transmission Movements Use a hoist or transmission jack that al lows precise control of transmission movements during installation 5 2 MOUNTING TO ENGINE Use the following procedure to mount the transmission to the engine Align one of the flexplate s bolt holes with the access opening at the front of the engine flywheel housing Lubricate the center pilot boss with molybdenum disulfide grease Molycote G or equivalent Install a headless guide bolt into one of the flex disk bolt holes in the flexplate adapter refer to Figure 4 3 Align the guide bolt with the flexplate hole at the access opening Push the transmission toward the engine while guiding the pilot boss on the flywheel into the flexplate hub adapter and the guide bolt into the hole on the flexplate Seat the transmission squarely against the engine flywheel housing no force is required If interference is encountered move the t
27. ed as Type C 4 fluid To ensure the fluid is qualified for use in Allison transmissions check for a DEXRONS III or C 4 fluid license or approval numbers on the container or consult the lubricant manufacturer Consult your Allison Transmission dealer or distributor before using other fluid types Fluid types such as Type F and universal farm fluids may or may not be properly qualified for use in your Allison transmission CAUTION Disregarding minimum fluid temperature limits can result in transmission malfunction or reduced transmission life When choosing the optimum viscosity grade of fluid to use duty cycle preheat capabilities and or geographical location must be taken into consideration Table 1 1 lists the minimum fluid temperatures at which the transmission may be safely operated without preheating the fluid Preheat with auxiliary heating equipment or by running the equipment or vehicle with the transmission in Neutral for a minimum of 20 minutes before attempting range operation Table 1 1 Transmission Fluid Operating Temperature Requirements Ambient Temperature Below Which Preheat is Required Viscosity Grade Celsius Fahrenheit MIL L 46167 51 60 MIL L 2104D 32 25 SAE 0W 20 30 22 DEXRON III 27 17 SAE 10W 20 4 SAE 10W 30 20 4 SAE 15W 40 15 5 SAE 30W 0 32 SAE 40W 10 50 1 6 TRANSMISSION FLUID AND FILTER CHANGE INTERVALS a Frequency Transmission fluid
28. eries bolts APPLIED 3 places Torque M6 X 1 00 IN bolt to 10 13 Nem 84 120 LB IN Torque 250 20 IN series bolts to 108 132 LB IN UNACCEPTABLE INSTALLATION Mount to a solid frame member Flatness of chassis mounting surface must not exceed 0 8 mm 037 10 09 MAX INSTALLED OPERATING ANGLE IN ALL DIRECTIONS 55 0 mm 2 17 MIN REQUIRED LOADING IN FOR CONNECTION TENSION ONLY REMOVAL ACCEPTABLE INSTALLATION Attachment must provide freedom of motion to allow cable loading in tension only no bending loads WIRING HARNESS Fuel control must not move the throttle sensor beyond the closed throttle position at any time R 152 0 mm 6 00 MIN ALLOWANCE RADIUS FULLY EXTENDED FULLY FORCE REQUIRED RETRACTED 26 7 6 0 LB MAX MOUNTING 475mm 187 LENGTH FULL THROTTLE 118 1 mm 4 65 CLOSED THROTTLE 95 2 mm 3 75 OPERATING BAND 22 9 mm 0 9 The location of the clamping bracket relative to the fuel lever at closed throttle must be maintained within this range Attach to engine or governor housing using clamp and shims as required Clamp must 93 45 mm 3 679 positively lock in cable groove 302mm 1 19 87 15 mm 3 431 HITCH PIN CLIP ENGINE FUEL LEVER Fuel lever attachment linkage or bracket must allow fuel lever to return to closed throttle position when sensor rod is maintained at full throttle position Attach the throttle
29. for the following conditions and correct them as appropriate Transmission mounts broken or worn out Bolts and other hardware damaged missing or incorrect solators rubber mounts damaged or missing Driveline angles runout balance or offsets which do not conform to the manufacturer s recommendations Driveline yoke slip joints freedom of movement damaged or worn out 29 correctly lubricated correctly indexed Driveline midship or hanger bearings damaged or misaligned Universal joints freedom of movement damaged or worn out correctly lubricated correctly indexed Vehicle differential backlash manufacturer s specification Universal joint coupling alignment and differential damage Cross frame members and rear support members condition and location PTO driven equipment shafts and couplings damaged or misaligned Auxiliary transmission shaft alignment alignment of yoke or flange backlash fluid leaks 4 4 COOLER FILTER AND LINES a Inspection Perform the following and correct any faulty conditions Transmission fluid cooler and related coolant lines Check for contamination clean and flush as necessary Inspect for deterioration Inspect for faulty connectors or kinks Clean and flush transmission fluid cooler both coolant and oil sides Pressure check both sides using a 276 kPa 40 psi air supply
30. ghten the bolts to the torque values recommended by the vehicle manufacturer 5 4 COUPLING TO DRIVELINE Couple the driveline companion flange or universal joint yoke to the flange or yoke on the transmission Use the bolts and torque values recommended by the vehicle manufacturer Check the universal joint angularity of all U joints in the driveline Determine if they are within specification 5 5 CONNECTING POWER TAKEOFF CONTROLS If not already mounted mount the PTO s onto the transmission refer to Check the PTO harness routing for kinks and sharp bends Avoid routing the cable close to exhaust pipes or manifold The PTO harness must not rub or interfere with adjacent parts 36 Connect controls to the PTO Check for proper PTO control operation CAUTION PTO units using transmission main pressure to engage the PTO gear must have a positive main pressure shut off at the solenoid valve when the PTO is not engaged Couple the PTO output to its driven equipment Check couplings or universal joints for correct assembly and alignment 5 6 CONNECTING COOLER Figure 5 1 shows typical cooler line installation MD 3070PT TO COOLER COOLER RETURN RIGHT VIEW TORQUE ON COOLER FITTINGS 54 68 N m 40 50 LB FT V01729 Figure 5 1 Torque Values of Typical Fluid Cooler Lines 5 7 CONNECTING SPEEDOMETER DRIVE The ECU through the VIM provides an electronic speedome
31. he diagnostic display mode was activated 1 12 TRANSMISSION STALL TEST AND NEUTRAL COOL DOWN CHECK a Purpose When a vehicle is performing unsatisfactorily use the stall test to determine if the malfunction is in the engine or in the transmis sion The neutral cool down check uses a two minute cooling period af ter the stall to gather fluid temperature data for troubleshooting b Transmission Stall Test Procedure The engine stall rpm under load is compared to the engine manufacturers specified rpm for the stall test NOTE The engine manufacturer s test data must be available for the stall test This data can be obtained from the engine manufacturer or from the equipment dealer or distributor You must know the stall speed of the engine torque converter combination If you have complete engine information such as model manufacturer and the installed torque converter information the Allison Transmission distributor or dealer can determine the stall speed of the engine torque converter combination installed in your vehicle by using SCAAN NOTE The Pro Link diagnostic tool can read sump temperature to show when normal operating temperatures have been reached and the temperature has stabilized lt Connect a tachometer the Pro Link diagnostic tool can read engine rpm of known accuracy to the engine and install a temperature probe into the converter out to cooler hose Bring the transmission to the nor
32. ission position them so that they do not interfere with transmission removal Disconnect the external wiring harness at the feedthrough harness connector On models prior to 1995 disconnect the external wiring harness at the transmission connector Prevent dirt or moisture from entering a disconnected connector Position the wiring harness so it does not interfere with transmission removal Disconnect the engine and output speed sensors 20 FEEDTHROUGH HARNESS MOUNTING PADS E 5 poe ASSEMBLY PADS ptt RE ES 5 EN N gt uA La D v TE lr ool ge ovk gt prol o 2 i y coor x 1 3 PORTS A X 1 d4 1 Poss NAMEPLATE um Aw ENGINE SPEED SENSOR SCAVENGE PUMP E01707 03 Figure 2 1 MD 3070PT Disconnect Locations TRANSMISSION CONNECTOR 01444 01 Figure 2 2 Transmission Connector Prior to S N 6510032369 21 2 3 UNCOUPLING FROM DRIVELINE ENGINE AND VEHICLE Disconnect the vehicle drive shafts from the transmission output flanges or yokes Position the disconnected shaft to avoid interference when removing the transmission 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
33. mal operating temperature range of 71 93 160 F 200 F WARNING Securely block the vehicle from moving chock the vehicle wheels and apply the parking brake and service brake Warn personnel to keep clear of the vehicle and its travel path Failure to do so can cause serious injury CAUTION DO NOT conduct a stall test in R Reverse range The torque produced in reverse range can damage the vehicle driveline or axle es Shift to any forward range CAUTION The stall condition causes a rapid rise in fluid temper ature never maintain the stall for more than 30 seconds at any one time Do not let the converter out fluid temperature exceed 149 C 300 F During stall conditions converter out temperatures rise much 6 faster than internal fluid temperature Do not use internal fluid temperature to determine the length of the stall condition If the stall test is repeated do not let the engine overheat With the vehicle blocked and wheels chocked parking and service brakes applied hold the engine at wide open throttle Record the maximum engine rpm Do not allow converter out fluid to exceed 149 C 300 F 18 Reduce engine rpm to idle and shift to N Neutral Raise engine speed between 1200 and 1500 rpm for 2 3 minutes to allow transmission to cool down Monitor converter out temperature If transmission temperature doesn t decrease refer to Section 1 12d c Stall Test Results NOTE
34. necessary confirm that it has been installed to ATD specification The TPS is self calibrating and therefore has no optimum closed throttle or 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 range with a difference of 85 to 130 counts between closed and full throttle the TPS is set correctly The Pro Link diagnostic tool can read TPS counts Watch the TPS movements as the controls move it through a full stroke Be sure the following conditions do not exist misalignment or obstruction to smooth movement through the full stroke idle and full throttle positions are not within an error zone refer to Figure 4 4 Error codes occur if the idle position is less than 14 counts or when the full throttle position is more than 233 counts Adjust so total stroke is within 0 COUNT 50 200 count band 258 COUNTS 14 COUNTS 233 COUNTS ERROR ZONE ERROR ZONE APPROX 19 mm 0 75 in STROKE 44 6 5 CLOSED WIDE OPEN THROTTLE THROTTLE 50 COUNTS 200 COUNTS l I FULLY FULLY RETRACTED EXTENDED AT REST Total Stroke 2 5 mm CT WOT 40 6 mm 0 1 in 15 2 22 9 mm 1 6 in omm 0 6 in 0 9 in 45 7 mm 85 130 Counts vee V00429 05 Figure 4 4 Throttle Position Determination Diagram 32 MOUNTING PROVISION BENDING LOAD Use M6 X 1 00 or 250 20 IN s
35. nsmission must be disassembled and closely inspected to find their source Metal contamination requires complete transmission disassembly Clean all internal and external hydraulic circuits cooler and all other areas where the particles could lodge CAUTION If excessive metal contamination has occurred replace the oil cooler and all bearings in the transmission 1 8 TRANSMISSION FLUID AND FILTER CHANGE PROCEDURE NOTE J Do not drain the transmission fluid if only filters are being replaced a Drain Fluid Drain the fluid when the transmission is at operating temperature 71 93 160 F 200 F Hot fluid flows quicker and drains more completely Remove the drain plug from the control module and the transfer case and allow the fluid to drain into a suitable container Examine the fluid as described in Paragraph 1 7 b Replace Filters Remove twelve bolts two filter covers two O rings two square cut seals and two filters from the bottom of the control module refer to Figure 1 2 NOTE J Lubricate the O ring inside the filter cartridges Pre lube and install an O ring on each cover assembly Install a square cut seal on each cover assembly Install the filters onto the cover assemblies CAUTION Do not use the bolts to draw filter covers to the sump This can damage the covers seals or sump Install filter and cover assemblies into the filter compartment Align each filter cover
36. oss at the center of the flywheel for damage or raised metal that prevents free entry into the crankshaft hub adapter c Starter Ring Gear Check the starter ring gear for excessive wear or damage d Transmission Mounting Flange Check the transmission mounting flange for raised metal dirt or if used pieces of gasket material e Transmission to Engine Mounting Flange Inspect the transmission to engine mounting flange for raised metal burrs or pieces of gasket material if used Remove any of these defects Inspect the threaded holes for damaged threads 3 2 INSTALLING OUTPUT FLANGE OR YOKE a Output Oil Seals Check the output oil seals for leaks or damage Replacement instructions are in the MD Series Service Manual SM2148EN Lubricate the oil seal 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 Check Yokes Check each flange or yoke for damage or wear The oil seal con tact surface must be smooth and regular to prevent oil leaking past the seal Rotate the flange during installation to prevent damage to the oil seal lip c Install Output Yokes Install the rear output yoke on the rear output shaft Tight en the nut to 610 815 N m 450 600 Ib ft Follow the same procedure for the front output yoke 23 3 3 INSTALLING PTO Access to the PTO mounting pads and
37. p Install two headless guide pins into the converter housing scavenge pump pad Tighten the pins b Install Gasket Install the special gasket over the guide pins ribbed surface away from the transmission c Mount the Scavenge Pump Mount the scavenge pump on the guide pins mesh ing the scavenge pump with the transmission s PTO drive gear Retain the scavenge pump by installing a bolt in the top bolt hole Install the remaining eight bolts and tighten the bolts to 51 61 N m 38 45 Ib ft 24 3 5 INSTALLING FILL TUBE AND SEAL a Location The fill tube may be mounted on either the right or left side The unused fill tube provision must have an expansion plug in the fill tube opening CAUTION Install the fill tube brackets with the correct length bolt Too long a bolt may cause cracks and leaks in the main housing Refer to the MD 3070PT 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 N m 18 21 Ib ft Install the expansion plug in the unused fill tube hole Tighten the plug to 1 3 N m 9 26 lb in 3 6 CHECKING PLUGS AND OPENINGS Carefully check all sides and the bottom of the transmission for loose or missing plugs a Pressure Plugs Check that 4375 20 UNF 2A pressure plugs are tightened to 10 13 N m 7 10 Ib ft b Fl
38. ral Run the engine at 1200 1500 rpm for two minutes to cool the fluid At the end of two minutes record the converter out fluid temperature Converter out fluid temperature should return to within the normal operating temperature range If the fluid does not cool during the two minute cool down check a stuck stator may be the source of the problem NOTE J You may use the Pro Link diagnostic tool to perform stall test and clutch test procedures Refer to the Pro Link User s Manual for specific instructions 19 REMOVING SECTION TRANSMISSION II 2 1 DRAINING TRANSMISSION Drain the transmission fluid before removing the transmission from the vehicle The transmission should be warm and the fluid allowed to drain completely Remove the drain plug from the control module and the transfer case Examine the drained fluid for evidence of contamination refer to Paragraph 1 7 Reinstall the drain plug Remove transmission fill tube if it interferes with transmission removal NOTE J A significant amount of fluid may drain from the hydraulic lines when they are disconnected from the transmission Disconnect all hydraulic lines from the transmission Remove the lines from the vehicle if they interfere with transmission removal Plug all openings to keep dirt from entering the hydraulic system 2 2 DISCONNECTING CONTROLS Disconnect or completely remove controls If controls are not removed from the transm
39. ransmission away from the engine and investigate the cause Align the bolts holes in the converter housing with those in the engine flywheel housing Install all transmission to engine bolts finger tight CAUTION The entire converter housing circumference must be flush against the engine flywheel housing before tightening any bolts DO NOT use the bolts to seat the housing 35 Tighten four bolts at 90 degree 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 N m 38 45 Ib ft or 716 14 bolts tightened to 73 88 N m 54 65 Ib ft Remove the guide bolt through the engine flywheel housing access opening Replace it with a self locking bolt Tighten the bolt finger tight NOTE J DO NOT tighten any flexplate to flexplate adapter bolts until all of the bolts have been installed and tightened finger tight e Rotate the engine crankshaft to install the remaining self locking bolts into the flexplate adapter After all bolts have been installed finger tight tighten them to 24 29 N m 18 21 Ib ft Install the flywheel housing access cover 5 3 INSTALLING TRANSMISSION MOUNTING COMPONENTS CAUTION Use the type and grade of mounting bolts recommended by the vehicle manufacturer Install all bolts washers spacer isolators or supports required to support the transmission in the vehicle frame Ti
40. return to the first code listed and repeat the sequence RECORD ALL THE CODES NOTE J You can also use Pro Link diagnostic tool to clear and retrieve the troubleshooting codes Refer to the Pro Link User s Manual or SA2828 for specific instructions HOLD OVERRIDE BUTTON BUTTON PUSHBUTTON Ee SPEED SEVEN SPEED SELECTOR LEVER SELECTOR LEVER SELECTOR V01458 01 Figure 1 3 Shift Selector e Troubleshooting When No Diagnostic Codes Are Present Always start with the basics Make sure the shifter is in the appropriate range Check the fluid level Make sure batteries are properly connected and charged Make sure electrical connections are properly made Check support equipment for proper installation and operation If the shifting process is rough give the shifts time to converge before assuming there is a problem Refer to the WT Troubleshooting Manual s General Troubleshooting of Performance Complaints section These troubleshooting charts list a variety of conditions that may or may not relate to the Electronic Control Some conditions and suggested checks include mechanical and hydraulic items If the troubleshooting charts refer you to an Electronic Control check use the diagnostic code troubleshooting information that best applies to the situation Use
41. s Attaching bolts not correctly tightened Improperly installed or damaged gasket Mounting face damaged Housing leak Filler pipe or plug seal damaged or missing Hiller pipe bracket dislocated cooler connector fittings loose or damaged Output shaft seals worn out or damaged Pressure port plugs loose Porous casting Leak at converter end Converter seal damaged Seal lip cut check converter hub for damage Garter spring missing from seal Converter leak in weld area or O ring seal Porous casting Fluid comes out of vent or fill tube Overfilled incorrect dipstick Plugged vent Water or coolant in fluid fluid will appear milky Incorrect electronic fluid level indication Drain back holes plugged 3 Visually inspect the suspected area Inspect all the gasket mating surfaces for leaks 4 If the leak still cannot be identified then clean the suspected area with a degreaser steam or spray solvent Clean and dry the area Operate the vehicle for several miles at varying speeds Inspect the vehicle for leaks If the source of the leak is still not identified use powder method or black light and dye method as explained below b Powder Method Clean the suspected area Apply an aerosol type white powder Operate the vehicle under normal operating conditions 11 Visually inspect the suspected area and trace the leak path over the white
42. temperature sensor on the internal harness Actual temperature readings can be made with the diagnostic tool A temperature gauge may be installed in the To Cooler line If equipped for them install a temperature probe capillary tube and bulb or a thermocouple If equipped with a capillary tube and bulb Tighten the adapter tight enough to prevent leakage Install the bulb into the adapter and tighten the nut Check the capillary tube for interference with other parts that might chafe or damage the tube Long tubes may require support clips or brackets 38 If equipped with a thermocouple Install the thermocouple and connect the leads Install and connect other electrical components such as heaters winterization equipment and pressure sensors If equipped install the pressure gauge tube or line Check that all unused hydraulic openings are plugged 5 9 FILLING HYDRAULIC SYSTEM Select a transmission fluid Fill the transmission with the required amount of fluid refer to Paragraph 1 8 Run the engine for about one minute and check the fluid level Paragraph 1 3 5 10 INSTALLATION CHECKLIST Complete the Installation Checklist in Section VI 39 SECTION CHECKS AND VI ADJUSTMENTS 6 1 INSTALLATION CHECKLIST Use this list after transmission installation As items are checked mark them off this list Torque Values 600 D OOO
43. ter speed signal If used consult the OEM for connection procedure 37 5 8 CONNECTING ELECTRICAL COMPONENTS NOTE J Allison World Transmission electronic control systems are designed and manufactured to comply with all FCC and other guidelines regarding radio frequency interference electromagnetic interference RFI EMD 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 World Transmission equipped vehicles to customer satisfaction For further information refer to the Electronic Controls Troubleshooting Manual TS2470EN a Procedure Remove the cover from the transmission feedthrough connector and carefully connect the transmission external wiring harness Keep dirt and debris out of the connector Connect the external wiring harness Connect the engine speed sensor and transfer case connector Connect the PTO s connector s The PTO connector is NOT part of the Allison Transmission external wiring harness Tighten the transmission wiring harness external connector bolt to 2 3 N m 18 25 Ib in Ensure the speed sensors the PTO connector and all other connectors are securely seated and latched A connector can be heard or felt to latch but confirm the latching by pulling on the connector NOT THE WIRES The transmission has a sump fluid
44. the telephone directory for the Allison Transmission service outlet nearest you Table 7 1 MD 3070PT Service Literature Publication Title Fublicadon Number Service Manual SM2148EN Parts Catalog PC2150EN Troubleshooting Manual TS2470EN Principles of Operation PO2454EN Operator s Manual OM2683EN Job Aid Card JA2506EN 44 i I o MT2923EN 199611 wwwW allisontransmission com Printed in USA 199611
45. the SELECT label The oil level information is sequentially displayed as in the following examples Select Monitor If the oil level is correct O L O K K J If the oil level is low If the oil level is high NOTE Select Monitor L L 1 Select Monitor L H I 1 Failure to meet any of the above conditions stops the two minute countdown One of the following codes displays on the shift selector to show the reason for the countdown interruption Once all conditions have been met the countdown resumes where it stopped CODE 50 59 65 70 79 89 95 CAUSE OF CODE Engine rpm too low Engine rpm too high Neutral not selected Sump oil temperature too low Sump oil temperature too high Output shaft rotation Oil level sensor failure If oil level cannot be checked and a code is issued indicating the reason the following type display appears Select Monitor O L 5 9 NOTE Report sensor failure to a distributor or dealer in your area Check the telephone directory for an Allison Transmission distributor or dealer near you Exiting The Oil Level Display Mode For a pushbutton shift selector Press any range selection button For a lever shift selector Press the DISPLAY MODE button or select a range b Manual Fluid Check Procedure Clean all dirt from around the end of the fluid fill tu
46. the space available to maneuver the transmission determine whether the PTO should be installed before or after the transmission is installed Use only the shims gaskets listed in the MD Parts Catalog W CAUTION DO NOT use cork or other soft gaskets to install the PTO NOTE J DO NOT use sealing compounds they are usually incompatible with automatic transmission fluid a Install Guide Pins included in the PTO installation kit Determine the re quired position of the guide pins in relation to the mounted position of the PTO The guide pins must align with the two blind holes in the PTO Install two headless guide pins into the converter housing PTO pad Tighten the pins b Install Gasket Install the special gasket over the guide pins ribbed surface away from the transmission c Mount the PTO Mount the PTO on the guide pins meshing the PTO driven gear with the transmission s PTO drive gear Retain the PTO by installing a bolt in the top bolt hole Install the remaining bolts Tighten all bolts to 51 61 N m 38 45 Ib ft 3 4 INSTALLING SCAVENGE PUMP Determine whether the scavenge pump should be installed before or after the transmission has been installed a Install the Guide Pins included in the scavenge pump installation kit Deter mine the required position of the guide pins in relation to the mounted position of the scavenge pump The guide pins must align with the two blind holes in the scav enge pum
47. thin the COLD RUN band the transmission may be operated until the fluid is hot enough to perform a HOT RUN check If the fluid level is not within the COLD RUN band add or drain as necessary to bring it to the middle of the COLD RUN band Perform a hot check at the first opportunity after the normal operating temperature of 71 93 160 F 200 F is reached d Hot Check Procedure CAUTION The fluid must be hot to ensure an accurate check The fluid level rises as temperature increases Operate the transmission in D Drive range until normal operating temperature is reached sump temperature 71 93 160 F 200 F converter out temperature 822 1042 180 F 220 F Parkthe vehicle on a level surface and shift to N Neutral Apply the parking brake and chock the wheels Allow the engine to idle 500 800 rpm With the engine running remove the dipstick from the tube and wipe clean Insert the dipstick into the tube and remove Check fluid level reading Repeat the check procedure to verify the reading NOTE J Safe operating level is within the HOT RUN band on the dipstick Figure 1 1 The HOT RUN band is between the HOT FULL and HOT ADD marks Ifthe fluid level is not within the HOT RUN band add or drain as necessary to bring the fluid level to within the HOT RUN band 6 35 mm lt
48. uid Drain Plug Check that the drain plug is tightened to 25 32 N m 18 24 Ib ft c Cleanliness Check the openings into which the cooler lines connect for defor mities or obstructions Check the transmission electrical connectors for cleanliness Clean electrical connections with an LPS cleaner only 25 SECTION PREPARING VEHICLE FOR TRANSMISSION INSTALLATION 4 1 ENGINE TRANSMISSION ADAPTATION REQUIREMENTS You must ensure a new transmission installation can be adapted to the vehicle s engine The measuremen ibed in de x ensure correct transmission to engine adaptation Refer to Figure 4 1 a Measuring Equipment The following measuring equipment is required 600 mm 24 inches precision caliper 50 100 mm 2 4 inches telescoping gauge 25 75 mm 1 3 inches outside micrometer Dial indicator and mounting attachments base posts and clamps 0 150 mm 0 6 inches depth micrometer b Flywheel Housing Pilot Bore Diameter The flywheel housing pilot bore diameter must measure from 447 68 447 81 mm 17 625 17 630 inches c Flywheel Housing Bore Runout Flywheel housing bore runout cannot exceed 0 51 mm 0 020 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
49. urement Limits Test Limit Viscosity 25 change from new fluid Carbonyl Absorbance 0 3 A 0 1 mm change from new fluid Total Acid Number 3 0 change from new fluid Solids 2 by volume maximum A Absorbance Units 1 7 TRANSMISSION FLUID CONTAMINATION a Fluid Examination At each fluid change examine the drained fluid for evidence of dirt or water A normal amount of condensation will appear in the fluid during op eration b Water Obvious water contamination of the transmission fluid or transmission fluid in the cooler heat exchanger water indicates a leak between the water and fluid areas of the cooler Inspect and pressure test the cooler to confirm the leak Replace leaking coolers NOTE J Cooler water can also be contaminated by engine oil be sure to locate the correct source of cooler water contamination c Engine Coolant Engine coolant in the transmission hydraulic system requires immediate action to prevent malfunction and possible serious damage Completely disassemble inspect and clean the transmission Remove all traces of the coolant and varnish deposits resulting from engine coolant contamination Replace friction clutch plates contaminated with engine coolant ethylene glycol d Metal Metal particles in the fluid except for the minute particles normally trapped in the oil filter indicate internal transmission damage If these particles are found in the sump the tra
50. using The breather prevents air pressure buildup within the transmission and its passage must be kept clean and open b Maintenance The amount of dust and dirt encountered will determine the fre quency of breather cleaning Use care when cleaning the transmission DO NOT SPRAY STEAM WATER OR CLEANING SOLUTION DIRECTLY AT THE BREATHER Spraying steam water or cleaning solution directly at the breather can force the water or cleaning solution into the transmission c Replacement Always use a wrench of the proper size to remove or replace the breather Pliers or a pipe wrench can crush or damage the stem and produce metal chips which could enter the transmission Tighten the breather to 12 16 N m 9 12 Ib ft 1 11 TROUBLESHOOTING a DO NOT SHIFT Light The DO NOT SHIFT light is usually located on the vehicle s instrument panel When the light is ON and accompanied by eight seconds of short beeps from the shift selector shifts are being restricted by the ECU This occurs when the ECU senses abnormal conditions During this time the Select digit on the shift selector is blank The transmission may continue to operate with inhibited shifting The ECU will not respond to shift selector requests Direction changes and shifts to and from neutral will not occur If the lever shift selector is moved while DO NOT SHIFT is indicated a continuous alarm sounds This alarm continues until the shifter is moved back to
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