Power / Drivetrain - Central States Bus Sales, Inc.
Contents
1. 40 41 POWER DRIVETRAIN Position the engine starter ground cable on the Negative post of the starter Position the starter ground cable from the ECU on the Negative post of the starter Torque the locknut to 12 ft Ib 4 16 27 Nm 4 Install the PDU starter power cable on the Positive terminal of the sole noid Torque the locknut to 12 ft Ib 4 16 27 Nm 4 Install the solenoid power cable from the ECU connector to the solenoid terminal Torque the locknut to 25 in lb 4 2 82 Nm 4 Ifthe power wire for the windshield washer motor was removed install it If the unit is equipped with shutters install the control valve on the inside left of the second crossmember deep U Position the breather air cleaner and install bolts in two places to secure the breather to the breathermounting bracket Torque new locknuts to 29 33 ft Ib 39 32 44 74 Nm Install the elbow between the breather and the turbo intake Torque the clamps to 6 5 7 5 ft Ib 8 81 10 17 Nm Install the air restriction indicator Install the intake duct Torque the clamp to 6 5 7 5 ft lb 8 81 10 17 Nm Ifthe baffles have been removed from the cooling pack install them Install the protective screen onto the baffle at the right hand side of the cool ing pack Position the intake duct and install bolts and new locknuts in 4 places Torque to 5 6 ft lb 6 78 8 13 Nm Install a new breather filter cartridge an2. Right Rear Side of Engine 2 Using a utility knife carefully remove the silicon sealant where the shift cable passes through the grommet in the firewall behind the dash Shift Cable Lower Cable Clamp 3 Remove cable clamps as necessary 4 Remove the lower shift cable clamp 5 Remove the cotter pin from the bottom shift cable Shift Cable Reinstallation To reinstall a shift cable reverse the removal procedure above 0 BLUE BIRD trunnion and pull it free of the transmission shift se lector lever POWER DRIVETRAIN Shift Cable Shift Cable Adjustment Improper adjustment ofthe shift cable can result in serious damage to the transmission When the Driver s shift con trol lever is squarely in Neutral the properly adjusted shift cable does not push the transmission s shift arm against either side of its travel Rather the shift arm is positioned in its centered detent position and the pressure between itand the cable end is relaxed 1 With the Driver s shift control lever in Neutral manu ally wiggle the transmission s shift arm slightly to ensure it is not under pressure from the cable If the cable is pressing the shift arm toward either side of its travel adjust it as follows 2 Remove the cotter pin from the trunnion pin which connects the cable end to the transmission s shift arm Then remove the trun nion pin This frees the shift arm to return to its relaxed center detent posi tion 3 Tu
3. 17 Install the transmission cooler hoses Torque the fittings at both ends of both hoses to 75 77 ft lb 101 69 104 34 Nm Do not use an adjustable wrench or pliers to tighten the fittings 0 BLUE BIRD POWER DRIVETRAIN 18 Ensure the drain plug and its sealing washer are in place in the transmission and tightened to 22 30 ft lb 30 40 Nm 19 Install a new main canister filter Ensure the magnet is installed on the top of the new filter Lubricate the new canister with a small amount of new transmission fluid and spin on until the canister just touches the converter Then tighten the filter ONE FULL TURN ONLY 20 Install no more than 3 5 US gallons 12 L for a new or rebuilt transmission Check repeatedly with the dipstick to ascertain the level is within the cold check band 21 Add or drain fluid to achieve the fluid level within this range before starting the engine 22 Proceed with the checking filling and draining operation as described in the instructions for the 100 000 mile 160 000 km 48 month maintenance proce dure 23 Check the system for leaks after the cold level check and after the transmis sion fluid has stabilized at operating temperature Shifter Removal To remove the shifter lever from the driver s area 1 Remove 4 screws from the corners of the dash housing the shifter cover 2 Remove the cotter pin from the top shifter inner cable trunnion 3 Pull the trunnion free of t
4. Belt Routing Engine Trim Cummins ISB 07 0 BLUE BIRD POWER DRIVETRAIN Transmission The Allison 2000 Series transmission is fully automatic torque converter driven and electronically controlled The transmission offers 5 forward speeds and 1 reverse gear All the clutches in the transmission are hydraulically actuated and spring re leased and feature automatic compensation for wear The gearing is of the helical type arranged in planetary sets Electronic control signals provide automatic gear selection in each drive range and automatic engagement of the torque converter lockup clutch The transmission has 4 major control systems connected by the Blue Bird wir ing harness The Transmission Control Module TCM engine throttle position sensor accelerator 3 separate speed sensors and a control valve module which contains 237 solenoid valves and a pressure switch module The accelerator speed sensors and pressure switch module transmit information to the TCM The TCM processes this in formation and then sends signals to actuate specific solenoids on the control valve module in the transmission These solenoids control both oncoming and offgoing clutch pressures to provide closed loop shift control This is accomplished by match ing RPM during a shift to a previously established profile that is programmed into the TCM The 2000 Series electronic control system has an adaptive shifting feature
5. inspect to 29 33 ft Ib 39 32 44 74 Nm in 4 places 8 Install the cooling pack onto the frame rails Carefully center the assembly between the rails Torque the mounting lock nuts to 29 33 ft Ib 39 32 44 74 Nm in 4 places 9 Install the diagonal braces Torque bolts to 70 80 ft Ib 94 91 108 47 Nm in 2 places Torque locknuts to 70 80 ft Ib 94 91 108 47 Nm in 2 places 10 Install all hoses and piping Torque constant torque clamps to cage the springs Torque wormgear type clamps to 40 ft Ib 4 54 23 4 Nm 11 Ensure the top radiator hose is installed in such a manner to maintain at least Ya clearance from the fan shroud 12 Ensure the protective loom is replaced on any hoses which had it originally installed 0 BLUE BIRD 232 0 BLUE BIRD vision SERVICE MANUAL 13 14 15 16 17 18 19 20 21 22 23 24 25 26 Install the breather mounting bracket Using new split ring lock washers torque capscrews to 33 58 ft lb 44 74 78 64 Nm in 3 places Install the transmission cooler hoses to the proper transmission port The To Cooler Port is on the left drivers side of the transmission and goes to the left side of the cooling pack Refer to the Transmission Section of this chapter for the complete installation instructions Install the exhaust pipe onto the turbo Refer to the Intake amp Exhaust chapter of this manual for more information Complete th
6. which helps optimize shift quality The feature monitors critical characteristics of clutch engagement and makes continuous adjustments to improve the next shifting sequence The transmission shift calibration is based on several different types of shifts full throttle partial throttle closed throttle upshifts downshifts etc Each shift is associated with specific speed and throttle positions To optimize each type of shift for normal driving the shift controls need to experience operation and shifting in a wide variety of conditions A drive in period under varying driving conditions is required for the Adaptive Controls to begin to optimize shifting under all conditions It may take as many as 5 shifts of each type to establish the automatic optimization sequence Torque Converter The torque converter has 3 main elements a pump the turbine and the stator The pump is the input component it is driven directly by the engine The turbine pro vides the output of the transmission the pump hydraulically drives it The stator multiples the torque When the pump is turning faster than the turbine the torque converter is multiplying the torque As the turbine reaches the speed of the pump the stator starts to rotate and torque multiplication stops The torque converter then acts as a fluid coupling device Series 2000 torque converters have a torque converter clutch a lockup clutch When this lockup clutch is engaged it causes th
7. 0 1mm change from new fluid Total Acid Number 0 3 change from new fluid Solids 2 by volume maximum A Absorbance Units 239 100 000 miles 160 000 km or 48 months Ascertain the oil vent breather is clean and free of dirt Do not spray the vent with steam or cleaning solvents Change both the filter and the transmission fluid Use only Transynd syn thetic transmission fluid or TES295 equivalent Use Blue Bird spin on filter cartridge number BB 0033381 Observe all applicable environmental health and safety regulations See the Introduction section of this service manual Drain the fluid while the transmission is at normal operating temperature 160 200 F 71 93 C Use caution to avoid serious burns Hot oil flows more quickly and drains more completely 1 Remove the drain plug from the oil pan and allow the fluid to drain into a suitable container 2 Examine the fluid to determine if there are metal fragments in it 3 Remove the canister filter 4 Remove the magnet from the top of the filter or the filter attachment tube 5 Clean any metal debris from the magnet anything larger than dust sized particles is cause for serious concern 6 Install the magnet onto the filter attachment tube 7 Lubricate the gasket of the new filter with new transmission fluid 8 Install the spin on filter by hand until the gasket touches the con verter housing 9 Tighten the filter ONE FULL TURN ONLY AF
8. POWER DRIVETRAIN gt Overview The Blue Bird Vision s engine transmission package is either a Caterpillar C7 or Cum mins ISB in line six cylinder diesel engine mated to an Allison PTS 2200 PTS 2500 or PTS 3000 Series five speed automatic transmission Both engine and transmission have electronic control modules For detailed instruction on engine maintenance and repair please consult the appropriate Caterpillar or Cummins publication Check with your Blue Bird Dealer or the nearest Caterpillar or Cummins dealer to ensure you are working with the proper publication Engine Transmission Removal 1 Drain the fluids from the engine transmission and hydraulic system into suit able containers for disposal in accordance with local state and federal regu lations 2 Remove the hood 3 Remove the front bumper 4 Remove the breather and the breather intake pipe Ensure the openings into the turbo and air pipes are covered to prevent introduction of debris MILENIO Always remove the Negative battery cable from the battery first and connect it last to avoid arcing 5 Remove the Negative battery cable from the battery 6 Remove the Positive battery cable from the battery 7 Remove the Negative cable from the alternator 8 Remove the ground cable holders from the breather bracket and secure the cable out of the way 9 Tag and remove the alternator power cable from the lower megafuse holder 10 Tag an
9. TER THE GASKET MAKES CONTACT WITH THE CONVERTER 10 Install the drain plug and sealing washer Torque the drain plug to 22 30 ft Ib 30 40 Nm 0 BLUE BIRD vision SERVICE MANUAL 11 Refill the transmission The capacity is approximately 7 4 quarts 7 L The transmission refill capacity is substantially less than the initial fill because a large amount of fluid remains in the transmission cavities after draining 12 After filling the transmission to the cold check level on the dip stick start the engine and allow it to idle for about a minute 13 With the service brakes applied shift to R for a few seconds back to N for a few seconds to D for a few seconds and then back to N 14 Allow the engine to idle at about 500 800 RPM and slowly release the 2 40 service brakes 15 With the engine running remove the dipstick and wipe it clean 16 Insert the dipstick into the tube and remove it Check the fluid level indicated on the dipstick Repeat at least twice for accuracy 17 If the fluid level is still within the cold check band the transmission may be operated until the fluid is up to operating temperature 18 If the fluid level is not within the cold check band you must drain or add fluid until it is before operating long enough to reach normal tem perature 19 Perform the hot check at the first opportunity after the transmission has been operated for about an hour and reached the no
10. d remove the power cable from the megafuse to the Power Distri bution Unit PDU at the megafuse 11 Tag and remove the power cable to the engine block heater at the mega fuse 12 Remove the cooling hoses and pipes See the Cooling System chapter of this manual for complete details 229 0 BLUE BIRD vision SERVICE MANUAL 13 Remove the cooling pack See the Cooling System chapter of this manual for complete details of the transmission cooler hoses 14 Remove the exhaust system from the turbo Refer to the Intake Exhaust chapter of this manual for more information 15 Tag remove and protect the fuel supply and return lines Protect the lines and the engine from contamination by debris or dirt as each fitting is re moved 230 16 Remove the power steering lines Refer to the Steering chapter of this manual for complete details 17 If so equipped remove the air compressor lines 18 Remove the transmission wiring See also the Transmission section of this chapter 19 Tag and remove all wiring from the Engine Control Unit ECU Remove the horn wiring 20 Tag and remove all wiring from the engine all senders etc 21 Remove the breathermounting bracket 22 If the unit is equipped with cooling pack shutters remove the control valve from the second deep U crossmember 23 Remove the driveline yoke Refer to the Driveline Section of this chapter for details 24 Remove the transmis
11. d secure the cover to prevent debris entering the turbo intake If necessary install drive belt See Belt Routing detail NUN Ensure that no debris or dirt contaminates either the fuel lines or the engine during this procedure 233 0 BLUE BIRD vision SERVICE MANUAL 42 Install the fuel supply line Ensure at least 20 inches of protective loom is installed Tighten the fitting finger tight and then tighten 1 flats further Use an open end wrench of the proper size Do not use an adjustable wrench or pliers to tighten 43 Install the fuel return line Ensure at least 20 inches of protective loom is installed Tighten the fitting finger tight and then tighten 1 flats further 44 Install the steering pressure line assembly Tighten fitting to finger tight Then using an open end or tubing wrench tighten 1 flats past finger tight 234 For complete information concerning the steering system see the Steering chapter of this manual 45 Install the supply line to the hydraulic pump Tighten the fitting 1 flats past finger tight 46 If the unit is equipped with air brakes replace the air compressor lines in ac cordance with the appropriate Caterpillar publication 47 Tighten the hardware on the gas assist spring to secure them to the frame and the hood Torque at 4 places to 16 18 ft Ib 21 69 24 40 Nm 48 Connect the wiring harness for the lights and horn 49 Fill the engine transmission and hydraulic
12. e engine 5 Never work under a bus with the engine running For more specific details on the Spicer Driveline components see the Spicer Life pub lication 3264 SPL 0 BLUE BIRD
13. e installation of the exhaust system Install the megafuse holders on the backside of the breathermounting bracket Tighten the four Philips head screws securely Loosely install a 125 amp Megafuse at the top holder and install a 200 amp Megafuse at the lower fuse holder Install alternator ground cable to the Power Distribution Unit PDU Torque the locknut at the alternator Negative terminal to 50 in Ib 4 5 65 Nm 4 Install 120 Ib cable ties to secure the ground cable Install the Positive alternator cable Torque the nut at the alternator end to 100 in Ib 4 11 30 Nm 4 Install the PDU power cable on the rearward post of the lower Megafuse holder install the copper bus bar between the rearward posts of the Mega fuse holders Torque locknuts to 8 ft lb 4 10 85 Nm 4 Install the intake heater cable power cable at the top Megafuse holder torque the locknut to 8 ft Ib 4 10 85 Nm 4 Install the engine end of the intake heater power cable Install the exciter wire on the alternator Torque to 25 in lb 4 2 82 Nm 4 Install wire tie to secure exciter wire Install engine wire harness Caterpillar harness to the Engine Control Unit ECU The ECU is located on the firewall Install the Blue Bird body harness to the ECU Position the PDU starter ground cable on the Negative post of the start er 27 28 29 30 31 32 33 34 35 36 37 38 39
14. e pump and turbine to be locked together so they rotate in unison at engine speed This provides direct drive through the transmission This type of operation maximizes engine braking and fuel econo my The lockup clutch is regulated by the shift controls and operates automatically The lockup clutch releases at lower speeds or when the TCM senses conditions re quiring it to be released The torque converter clutch features a damping mecha nism which reduces the transmittal of engine induced torsion vibration through the transmission 0 BLUE BIRD VISION service manuan Planetary Gears and Clutches A series of 3 helical planetary gear sets and shafts provide the mechanical gear ratios and direction of travel necessary for the bus These planetary gear sets are controlled by 5 multiple clutches that work in pairs to produce 5 forward speeds and 1 reverse gear The clutches are controlled hydraulically in response to electronic signals from the TCM to the individual solenoids Cooler Excessive heat in the transmission is dissipated by circulating the transmission fluid through a section of the radiator The transmission cooler lines connect directly to 238 the bottom of the radiator Filters An outboard filter is located near the front of the transmis sion on the driver s side Blue Bird part number 0033381 This spin off canister type filter must be replaced after the first 5 000 miles 8000 km and thereafter at 50 000 mi
15. equipped 4 Remove the top dipstick bracket clamp 5 Remove the shift cable trunnion from the shift lever at the transmission Dis card the cotter pin 6 Remove the shifter cable mounting bracket Discard split ring lock washers 7 Remove cable clamps as necessary to position the shifter cable out of the way 8 Remove the capscrew 31 at the bottom dipstick bracket Discard the split ring lock washer Store the dipstick tube and dipstick in a safe location INTI Ensure all openings and hoses are sealed to prevent contamina tion 9 Remove all wiring harness connections 10 Secure the driveline with nylon straps before continuing 11 Remove the yoke straps at the driveline Discard capscrews and straps Refer to the Driveline section of this service manual for more information 12 Ifthe unitis equipped with a mechanical park brake refer to the Park Brake section of this Service Manual for removal adjustment and in stallation of the Park Brake 0 BLUE BIRD POWER DRIVETRAIN Gm WILLIS The transmission must be supported before pro AN Wl bu ceeding 13 Remove the access plate on the bottom of the flywheel hous ing 14 Remove the 6 capscrews 23 from the flexplate Index the engine to access all the capscrews 15 Remove capscrews 24 from 12 places around the torque converter bell housing Discard the splitring lock washers 243 16 Carefully pull the transmission away from
16. he shift selector Mark the hole in the shifter plate from which the trunnion was removed to facilitate assembly 4 Remove the clamping bolt and nut assembly from the outer cable clamp 5 Remove the 4 retaining bolts two each side from the shift selector mount Inner Cable Trunion ing bracket and pull the shifter straight out Retaining Bolts 2 per side Outer Cable Clamp BLUE BIRD VISION service manua Shifter Reinstallation Installation of the shifter is essentially the reverse order of the removal Position the shifter in the shifter mounting bracket Install 4 mounting bolts The threads must not protrude into the shifter assembly more than 38 inch es 9 652 mm Torque the retaining bolts to 6 9 ft Ib 8 13 12 20 Nm 2 Loosely route the shifter cable through the outer cable clamp and position the top trunnion in the previously marked hole of the shift selector Install a new cotter pin bend each leg at least 45 to hold it in position 3 Ensure that both the shift selector lever and the transmission are in the N neutral position 4 Torque the outer cable clamp bolt assembly to 6 9 ft Ib 8 13 12 020 Nm 5 Ensure the shift selector operates properly 6 Position the plastic dash cover onto the metal mounting bracket and secure with 4 screws Flywheel Access Plate Shift Cable Removal SE 1 Remove the shift cable in accordance with Shifter Removal steps 1 through 5 above
17. ift lever on the shift selector shaft of the transmission and install the hexnut 104 While holding the lever stationary torque to 15 20 ft Ib 20 34 27 12 Nm Do not allow the shift selector shaft to turn 9 Position the shift cable trunnion in the top hole of the shift lever at the trans mission Secure it with a new cotter pin Bend each leg of the cotter pin at least 45 to secure it 244 10 Install the shift cable mounting bracket with 2 capscrews using new split ring lock washers Torque to 75 ft Ib 101 69 Nm 11 Position the dipstick tube in the transmission 12 Install the bottom dipstick tube bracket with capscrew 31 use a new split ring lock washer Torque to 18 21 ft Ib 24 40 28 47 Nm 13 Install the top dipstick tube bracket clamp Torque the bolt to 20 ft Ib 27 12 Nm 14 Install the dipstick 15 Connect all wiring harnesses 16 If the cooler hose adapter fittings have been removed replace them as fol lows if not skip to step 17 16 1 Ensure both the threads of the fittings and the radiator are clean 16 2 Start the adapters into the appropriate location on the radiator at least 1 full thread 16 3 Apply Loctite 557 pipe sealant with Teflon to the exposed threads of the fitting Follow the directions and warnings on the package 16 4 Tighten the adapters to finger tight then using an open end wrench tighten 11 2 turns Ensure the fittings are oriented as marked at re moval
18. les 80000 km or 24 months intervals whichever is the first to occur Use only Transynd synthetic transmission fluid or TES 295 equivalent The internal filter needs to be changed only during transmission overhaul Transmission Maintenance Daily Check that the engine will not start with the shifter lever in any position other than N neutral Before the trip check the transmission fluid level See the cold fluid level check below for instructions Check the transmission fluid level at the end of the trip to accomplish the hot level check below Notice if there is a burned odor to the transmission fluid Notice if the transmission shifts rough or fails to shift 5 000 miles 8000 km or 6 months Clean and inspect the linkage look for missing cotter pins locknuts etc Carefully inspect the transmission and all hoses look for signs of leaks wear and abrasion Check for worn or frayed electrical connectors or wires Check the throttle wiring for loose or frayed wires or connectors e Check the breather vent screen at the top rear of the transmission See Trans mission Removal illustration 0 BLUE BIRD POWER DRIVETRAIN Obtain fluid analysis for maximum efficiency Refer to the Technician s Guide for Automatic Transmission Fluid publication number SA2055 for more de tails Viscosity 20 change from new fluid Carbonyl Absorbance 0 3 A
19. rmal operat ing temperature of 160 200 F 71 93 C For more technical information consult the appropriate Allison publication or visit the Allison web site www allisontransmission com TITLE PUBLICATION Service Manual SM3191EN Parts Catalog PC3062EN Parts Catalog CD CD3062EN Electronic Troubleshoot TS3192EN Operation Principals PO3065EN Mechanics Tips MT3190EN The above publications are available from SGI Inc Attn Allison Literature Fulfillment 8350 Allison Avenue Indianapolis IN 46268 Toll Free 888 666 5799 International 317 471 4995 0 BLUE BIRD POWER DRIVETRAIN Dipstick Bracket Clamp amp I Breather Vent Flywheel Plate Shift Cable E Shift Cable Trunnion t Cable Mounting Bracket Clamp Transmission Cooler Hoses Transmission S El El vision SERVICE MANUAL Transmission Removal Observe all safety precautions and warnings in the Introduction chapter of this man ual 1 Remove the drain plug at the bottom of the transmission fluid pan to drain the transmission fluid into a suitable container for lawful disposal 2 Drain the transmission cooler hoses and the transmission cooler section of the radiator by removing the cooler hoses at the transmission fittings If the adapter fittings are removed from the bottom of the radiator mark the ori 242 entation of each to facilitate assembly 3 Remove the electronic leads from temperature sender if so
20. rn the trunnion pin on the threads of the cable end so that it aligns with relaxed shift arm Then reattach the trunnion to the shift arm and secure it with a new cotter pin 4 Recheck the shifting by operating the Drivers shift control lever Trunnion Pin Transmission Shift Arm Cotter Pin BLUE BIRD vision SERVICE MANUAL Drive Line The purpose of the driveline is to transmit torque from the engine to the drive wheels of the vehicle CEN Before continuing with these instructions please refer to the safety instructions in the Introduction Section of this Service Manual Removal To remove the driveline from the transmission 248 1 Mark the driveline section to be removed to show the installation orientation The driveline must be replaced correctly to avoid out of phase problems 2 Carefully support any driveline components that will be left without the normal operational support members hanger bearings 3 Remove and discard the capscrews and straps at the universal joints necessary to remove the desired driveline section Reinstallation 1 Carefully position the driveline components while observing the pre viously marked phase indications 2 Install new straps and hardware at the universal joints Torque the capscrews to 45 50 ft Ib 61 01 67 79 Nm 3 Lube all grease fittings with NLGI number 2 EP lubricant 4 Ensure all driveline guards are securely in place before starting th
21. sion shifter cable See the Transmission Section of this chapter for more information 25 Support the engine and transmission assembly with a suitable lifting de vice 26 Remove the rear motor mount bolts 27 Remove the front engine mounts 28 Carefully lift the engine transmission assembly and move it toward the front to remove it from the chassis 0 BLUE BIRD POWER DRIVETRAIN Engine Reinstallation Installation of the engine transmission assembly is accomplished in the reverse order of the removal instructions above 1 Carefully position the engine and transmission assembly and lower into place on the motor mounts Hold the engine off the mounts far enough to insert the Isolator and the flat washer into the joint at each side 2 Ensure the front motor mount bolts align with the holes in the deep U cross member 23 1 3 Install 2 new bolts in the rear motor mounts Use new hardware and new isolators Torque locknuts to 142 154 ft Ib 192 53 208 80 Nm 4 Install new hardware and isolators in the front motor mounts Install bolts with the hexhead up Torque locknuts to 142 154 ft Ib 192 53 208 80 Nm 5 Install the transmission yoke Use new capscrews and straps Torque to 45 60 ft Ib 61 01 81 35 Nm 6 Install the transmission shifter cable See the Transmission Section for de tails 7 Prior to installing the cooling pack onto the frame rails check the torque value on the lock nuts They should
22. system with the necessary fluids in accordance with the instructions in the Cooling Transmission and Steering Sections of this service manual Also refer to the appropriate OEM publica tions for critical information 50 Connect the Negative battery cable and then connect the Positive bat tery cable to prevent arcing and possible explosion Always refer to the appropriate OEM publication for instruction on their products See the Caterpillar Operation and Maintenance Manual for fluid specifications and quantity of the engine Consult the Allison publication for critical information concerning the transmission 0 BLUE BIRD POWER DRIVETRAIN Engine Block Heater Element 235 Fan Clutch Starter TORQUE SPECIFICATIONS ITEM TORQUE 28 56 58 LB FT 142 154 LB FT 112 132 LB FT 18 22 LB FT 120 133 LB FT 33 35 LB FT BOSCH ALT NUT 55 59 LB FT L N ALT NUT 70 80 LB FT Engine Trim Cat C7 07 BLUE BIRD vision SERVICE MANUAL TORQUE SPECIFICATIONS TORQUE Clutch 21 130 140 FT LB 27 112 132 FT LB 25 57 FT LB 26 57 FT LB 31 56 58 FT LB 38 38 42 FT LB MR L LEECE NEVILLE ALT NUT 70 80 FT LB DEALS SA BOSCH ALT NUT T 55 59 FT LB 2 3 6 NOIR 7 e E 4 ALT BOLTS 33 35 FT LB Starter Heater Valve Alternator Heater Valve Engine Block Heater Element alternator waterpump tensioner
23. the engine and lower to remove Fiywheel Access Plate For information regarding the repair of the Allison 2000 Series please refer to the appropriate Allison publication and your Blue Bird Distributor Transmission Reinstallation 1 With the repaired transmission on an appropriate cradle roll it carefully into position Lubricate the nose of the torque converter where it pilots into the crankshaft hub adaptor with NLGI Grade 2 grease 2 Install the flexplate to the adapter ring with 6 capscrews 23 Torque as you go to 38 45 ft Ib 51 52 61 01 Nm 3 Install access plate and shift cable clamps Torque the capscrews to 20 ft Ib 27 12 Nm 4 Install 12 capscrews 24 use new split ring lock washers Torque as you go to 36 43 ft Ib 48 81 58 30 Nm 5 Position the driveline journals in the yoke Using new straps and hardware torque to 45 60 ft Ib 61 01 81 35 Nm 6 Connect all electrical harnesses 7 If equipped with a mechanical Park Brake connect and adjust it according to instructions in the Hydraulic Brakes chapter of this manual 8 Ifthe NSBU has not been removed skip to step 9 Otherwise 8 1 Position the NSBU over the shift selector shaft of the transmission En sure the shift selector shaft is in the neutral position 0 BLUE BIRD vision SERVICE MANUAL 8 2 Install 2 mounting capscrews Torque the forward capscrew first then the rearward to 18 21 ft lb 24 40 28 47 Nm 8 3 Position the sh
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