Mechanic`s Tips 700 Series With Hydraulic Controls
Contents
1. y FULL TOP OF ADD OIL PAN Os A L COLD RUN BAND FILL TUBE HOLE 60 120 F 16 49 C Approximate dimension OEM customer to establish cold run band at installation 02372 Figure 2 3 Fluid Level 7 and 8 Inch Deep Oil Pan d Cold Test NOTE The only purpose of the cold test is to determine if the transmission has enough fluid to be safely operated until a hot test can be performed Run the engine for at least one minute Shift to D Drive and then to R Reverse to clear the hydraulic circuits of air The sump temperature should be between 60 120 F 16 50 C Park the vehicle on a level surface and shift to N Neutral Apply the parking and or emergency brakes and allow the engine to idle 500 800 rpm Chock the wheels of the vehicle With the engine running remove the dipstick from the fill tube wipe the dipstick clean and re insert it into the fill tube pushing down until it stops Remove the dipstick again and determine the fluid level If the fluid is within the COLD RUN band refer to Figure 2 4 the fluid level is satisfactory for operating the transmission until the fluid is hot enough to determine a HOT RUN fluid level If the fluid level is not within the COLD RUN band add or drain fluid as necessary to bring the level to the middle of the COLD RUN band Test for a hot fluid level at the first opportunity after the normal operating2. Allison Transmission Mechanic s Tips 700 Series With Hydraulic Controls MT1366EN 2006 APRIL Ti Ds MT1366EN Allison Transmission 700 Series With Hydraulic Controls HT 740 HT 740FS HT 747 HT 754CR HT 750DR DB CT CLT CLBT 750 754 DB A Allison Transmission Allison Transmission General Motors Corporation P O Box 894 Indianapolis Indiana 46206 0894 www allisontransmission com Printed in USA Copyright 2006 General Motors Corporation NOTES TABLE OF CONTENTS SECTION INTRODUCTION 1 1 ABOUT THIS MANUAL sese me di Ret ann a 9 SECTION PREVENTIVE MAINTENANCE 22 32 23 2 4 2 5 2 6 2 3 2 8 2 9 2 10 2 11 2 12 PERIODIC INSPECTION AND CARE 15 IMPORTANCE OF PROPER TRANSMISSION FLUID LEVEL 15 AERATED FLUID 4 0 2325 obo S dese benek 15 FLUID LEVEL TEST PROCEDURES 4 LARA 16 KEEPING TRANSMISSION FLUID CLEAN 23 AUTOMATIC TRANSMISSION FLUID RECOMMENDATIONS 23 FLUID TEMPERATURES cee ee a 24 TRANSMISSION FLUID AND FILTER CHANGE INTERVALS 24 TRANSMISSION FLUID CONTAMINATION 27 AUXILIARY FILTER 20 sa PRESS 29 BREATHER su 4 was Dow NE a A ek eL e 30 TRANSMISSION STALL TEST AND NEUTRAL COOL DOWN gc se ne 30 SECTION REMOVING TRANSMISSION FROM VEHICL
3. 2 3 inch outside micrometer Kent Moore J 26900 25 Dial indicator and attachments required Kent Moore J 26900 25 to mount base and posts 18 inch straight edge The 24 inch vernier caliper can be used as a precision straight edge 0 6 inch depth micrometer set More detailed information is available in Service Information Letter 60 TR 81 latest revision available from Allison distributors or dealers and on the internet at www allisontransmission com Measure the flywheel housing bore diameter Limits 20 125 20 133 inch 511 18 511 38 mm Measure the flywheel housing bore runout tolerance Limit 0 012 inch 0 305 mm maximum Measure the flywheel housing face runout tolerance Limit 0 012 inch 0 305 mm T I R maximum Measure the crankshaft hub pilot diameter or when used the hub adapter pilot diameter Limits 2 437 2 439 inch 61 90 61 95 mm Measure the crankshaft hub face runout tolerance or when used the installed hub adapter face squareness Limit 0 0005 inch maximum per inch 0 013 mm per cm of measured diameter Measure the crankshaft hub pilot eccentricity or when used the installed hub adapter pilot eccentricity Limit 0 005 inch 0 13 mm TI R maximum The flatness adjacent to each converter mounting bolt hole measurement is not a required measurement for HT or CT 700 flexplates 42 5 2 Measure the flexplate flatness at the converter mounting bolt hole
4. d Hydraulic input retarder Adjustment full open closed Ease of operation Drive Line Inspect for proper indexing of universal joints Inspect for proper driveshaft angles Determine differential backlash Lubricate universals and slip joints Hydraulic system Recommended fluid refer to Sufficient fluid in transmission Dipstick properly marked Fill cap tight Fill tube tight at oil pan Breather clean free of restriction Look for fluid leaks during operation Power Takeoff Backlash properly established Controls connected and operative Properly coupled to driven equipment Instruments and Electrical Equipment Speedometer Fluid temperature gauge Wiring and electrical connections Reverse signal switch Neutral start switch 61 Section VIII CUSTOMER SERVICE 8 1 OWNER ASSISTANCE There are distributors and dealers around the world ready to stand behind every Allison Transmission product Any situation that arises in connection with the sale operation or service of your transmission will be handled by the distributor or dealer in your area Refer to the Worldwide Sales and Service Directory SA2229EN for a current listing of Allison Transmission authorized distributors and service dealers 8 2 SERVICE LITERATURE Additional service literature is available as shown in the following table This service literature provides fully illustrated instructions for the operation maintenance
5. 2 6 7 8 9 10 11 12 13 INSTALLING TEMPERATURE AND PRESSURE SENSORS ELECTRICAL COMPONENTS Install temperature sensors capillary tube and bulb or thermocouple into the converter housing or hydraulic input retarder valve Refer to Figure 6 1 through Figure 6 5 for various locations Tighten the inch pipe thread adapter sufficiently to prevent leakage Install the bulb into the adapter and tighten the nut into the adapter Be sure the capillary tube does not interfere with parts that might chafe or damage the tube Long tubes may require clips or brackets for support Install electrical temperature sensors into the proper openings refer to Figure 6 1 through Figure 6 5 Connect electrical leads to the sensors Be sure that all openings in hydraulic input retarder models that require plugs are plugged refer to Figure 6 1 through Figure 6 5 NOTE The type and location of the neutral start switch is optional A threaded opening in the left side of the transmission can be used for installation if desired refer to Figure 6 9 Install the neutral start switch if so equipped into the left side of the transmission housing refer to Figure 6 9 The switch must include an aluminum washer gasket approximately 0 090 inch 2 29 mm thick for earlier models and 0 030 inch 0 76 mm thick for later models Tighten the switch to 50 60 Ib ft 68 81 N m Connect the wire leads that serve the neutral s
6. pump gear backlash before installing the PTO On PTO assemblies that require pressure lubrication install the lubrication tube fittings The lubricating fluid comes from the line returning to the transmission from the oil cooler Fluid should be directed to the PTO lubrication circuit after passing through a 0 060 inch 1 52 mm restriction maximum orifice size permitted is 0 110 inch 2 79 mm for the engine driven PTO or 0 032 inch 0 81 mm restriction for the turbine driven PTO This restriction is usually provided in the PTO CAUTION PTO units using transmission main pressure to engage the PTO drive gear must have a positive main pressure shut off at the solenoid valve when the PTO 15 not engaged 4 6 CONNECTING SHIFT MODULATOR CONTROL Connect all electrical pneumatic or vacuum modulator controls after the transmission is put into the vehicle If using mechanical modulator control refer to Paragraph 6 9 4 7 INSTALLING OIL FILL TUBE If the oil fill tube was removed install it before the transmission is put into the vehicle unless its presence will interfere with transmission installation 1 Install the oil fill tube onto the oil pan boss If the tube is attached to the oil pan by a nut tighten the nut to 90 100 Ib ft 123 135 N m or for 4 inch pan models tighten the nut to 40 50 Ib ft 54 68 N m CAUTION Be sure that the proper length bolts are used Using bolts K that are too long may cause cracks lea
7. service overhaul and parts support of your transmission To be sure that you receive maximum performance and service life from your transmission you may order publications from SGI Inc Attn Allison Literature Fulfillment Desk 8350 Allison Avenue Indianapolis IN 46268 TOLL FREE 888 666 5799 INTERNATIONAL 317 471 4995 62 Table 8 1 Available Service Literature HT 740 740FS 747 754CR 750DR CT CLT CLBT 750DR DB 750 754 DB Operator s Manual OM1334EN OM1475EN OM1772EN Service Manual SM1270EN SM1314EN Parts Catalog PC1268EN PC1315EN Parts Catalog CD ROM CD1268EN CD1315EN Technician s Guide Inspection GN2033EN GN2033EN Analysis Troubleshooting Manual TS1838EN Worldwide Sales and Service SA2229EN SA2229EN Directory Also available on the internet at www allisontransmission com Preventive Maintenance Oil Field Applications 63 e Anson MT1366EN 200604 www allisontransmission com Printed in USA 200606
8. sump temperature of 160 F 200 F 71 C 93 C has been reached Repeat the test to verify the reading If the readings are inconsistent inspect the breather to be sure it is clean and not clogged 20 e Hot Test NOTE The fluid level rises as the fluid temperature increases The fluid must be hot to be sure of an accurate fluid level test TRANSMISSION TO OIL PAN SPLITLINE TOP OF OIL PAN WITH 6INCH DEEP PAN DIMENSIONS ARE IN INCHES MILLIMETERS PROCEDURE 120 6 USE HOT RUN BAND FOR 160 200 F 71 93 C USE COLD RUN BAND FOR 60 120 F 16 499C NOTE This illustration is not a template Placement of the markings will vary according to the angle of the dipstick protruding into the fluid Dimensions shown are in the vertical plane Approximate dimension OEM Customer WITH 7 OR 81 2 INCH DEEP to establish cold run band at installation V02374 Figure 2 4 Dipstick Markings Locations 21 FLUID DRAIN PLUG 34 14 NPTF FILL PIPE AND LEVEL INDICATOR V02375 Figure 2 5 Dropbox Fluid Levels Front View pa Drive the vehicle until the transmission fluid reaches normal operating temperature 60 200 F 71 939C sump temperature b 80 220 F 82 104 C converter out temperature 2 Park the vehicle on a level surface and shift to N Neutral Apply the parking brake and or emergency brakes and chock the wheels Allow the
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10. ER 44 SECTION VI INSTALLING TRANSMISSION INTO VEHICLE 6 1 6 2 6 3 6 4 6 5 6 6 6 7 6 8 6 9 6 10 6 11 6 12 6 13 6 14 6 15 HANDLING asisi esli CX Deo Ode kms 46 MOUNTING TO ENGINE ENGINE MOUNTED MODELS 46 INSTALLING MOUNTING COMPONENTS 47 COUPLING TO ENGINE REMOTE MOUNTED MODELS 47 COUPLING TO DRIVELINE 47 CONNECTING COOLER AND FILTER LINES 48 CONNECTING SHIFT SELECTOR CONTROL 50 CONNECTING HYDRAULIC INPUT RETARDER CONTROL 52 CONNECTING MODULATOR CONTROL 52 CONNECTING POWER TAKEOFF PTO CONTROLS 56 CONNECTING PARKING BRAKE CONTROL 56 CONNECTING OUTPUT DISCONNECT SHAFT CONTROLS DROPBOX a amaa ii Voted ES ROT TERM 56 CONNECTING SPEEDOMETER DRIVE 56 INSTALLING TEMPERATURE AND PRESSURE SENSORS ELECTRICAL COMPONENTS ou 024 woman an nee REOR OX a 57 FILLING THE HYDRAULIC SYSTEM 58 SECTION VII TESTS AND ADJUSTMENTS 7 1 7 2 ENGINE TRANSMISSION ADAPTATION REQUIREMENTS 59 INSPECTING FLEXPLATE DRIVE ASSEMBLY ENGINE MOUNTED MODELS 60 SECTION VIII CUSTOMER SERVICE 8 1 OWNER ASSISTANCE 8 2 SERVICE LITERATURE NOTES TRADEMARK USAGE The following trademarks are the property of the companies indicated TranSynd is a trademark of Castrol Lt
11. F 82 104 C WARNING When conducting a transmission stall test the vehicle MUST BE prevented from moving Apply the parking brake and service brakes chock the wheels and take any other steps necessary to keep vehicle from moving Warn personnel to keep clear of the vehicle and its travel path Failure to do so can cause serious injury CAUTION Never maintain the stall condition for more than 30 seconds at any one time because of the rapid rise in fluid temperature Do not let the converter out fluid temperature exceed 300 F 149 C Do not rely on converter out fluid temperature to limit stall duration During stall conditions internal temperatures rise much faster than converter out fluid temperature If the stall test is repeated do not let the engine overheat 2 With the wheels chocked and the parking and service brakes applied shift to D Drive Then accelerate the engine to wide open throttle Stabilize the converter out fluid temperature at 255 F 107 C Record the engine speed 3 Reduce engine speed to idle and shift to N Neutral c Neutral Cool Down Test Procedure The neutral cool down test procedure determines if the transmission fluid cools following an engine load condition Perform this test immediately after the engine speed has been recorded in the stall test 1 Record the converter out fluid temperature 2 With the transmission remaining in neutral run the engine at 1200 1500 rpm for two mi
12. and components in the vicinity of the installation path Be sure that the bottom of the transmission pan is not bent inward This can cause the pan to come in contact with the internal suction screen resulting in starvation of the transmission charging pump Use a hoist or transmission jack that permits precise control of transmission movements during installation MOUNTING TO ENGINE ENGINE MOUNTED MODELS Align one of the twelve bolt holes in the flexplate assembly with the access opening at the front of the engine flywheel housing Install a headless 20 guide bolt into one of the flexplate bolt holes in the flywheel refer to Figure 3 1 Align the guide bolt with the flexplate hole at the access opening 3 Lubricate the center pilot boss with molybdenum disulfide grease Push the transmission toward the engine while guiding the pilot boss on the flywheel into the flexplate hub adapter and the guide bolt into a hole in the flexplate Seat the transmission squarely against the engine flywheel housing No force is required if interference is encountered move the transmission away from the engine and investigate the cause CAUTION The converter housing must be flush against the engine flywheel housing before tightening any bolts Do not use the bolts to seat the housing CAUTION Do not tighten any flywheel bolts until all of the bolts have 6 been installed finger tight Align the bolt hol
13. engine Remove the adapter ring and or gasket if used N Raise or lower the transmission as required to remove it from the vehicle 3 6 REMOVING OUTPUT FLANGE OR YOKE CAUTION The use of an impact wrench requires a means to hold the flange Failure to hold the flange can cause internal damage to the transmission When replacing the transmission it may be necessary to transfer input and output flanges or yokes to the replacement transmission If the flanges or yokes are retained by a large self locking nut follow these specific procedures to remove the nut 1 Before removing the self locking nut determine if there are any notches cut into the wrenching flats If there are five notches remove the nut and discard 2 If there are less than five notches or none at all remove dirt and burrs from the shaft threads Loosen the nut until there is about inch gap between the nut and flange Determine the running torque as the nut is being removed The first time the nut is removed no notches running torque must be at least 400 Ib in 45 N m Each additional time the nut is removed one to four notches running torque must be at least 300 Ib in 34 N m Discard the nut if it does not meet the running torque limit 3 7 REBUILD OVERHAUL INSTRUCTIONS Refer to the current edition of Service Manual SM1270EN HT 700 or SMI314EN CT 700 for rebuilding or overhauling the transmission 35 4 1 PREP
14. engine to idle 500 800 rpm With the engine running remove the dipstick wipe it clean and re insert it into the fill tube pushing down until it stops Remove the dipstick again and determine the fluid level The safe operating level is anywhere within the HOT RUN band refer the dipstick If the level is not within this band add or drain fluid as necessary to bring the level to the top of the HOT RUN band DO NOT OVERFILL 4 Repeat the test to verify the reading If the readings are inconsistent inspect the breather to sure it is clean and not clogged f Dropbox Fluid Level Determination With the engine at idle 500 800 rpm the proper FULL and ADD fluid levels in the dropbox are shown in refer to Figure 2 5 These levels are on a vertical line through the bottom output shaft The FULL and ADD marks on the dipstick should coincide with the fluid levels shown in refer to Figure 2 5 If fluid level is above the FULL line drain fluid as required to bring it to the proper level If fluid is below the ADD line add fluid as required to bring it to the proper level 22 2 5 KEEPING TRANSMISSION FLUID CLEAN 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 Transmission fluid must
15. mm below this scribed line scribe another line across the dipstick this represents the bottom of the HOT RUN band and the top of the COLD RUN band Measure down 1 25 inches 32 mm and scribe the bottom line for the COLD RUN band Add transmission fluid to the transmission through the fill tube opening after dipstick calibration is completed Be sure to use proper transmission fluid and fluid containers as discussed in Bections 2 5 2 6 Refer to Table 2 1 for approximate transmission fluid capacity c Fluid Level Test WARNING To help avoid personal injury or property damage caused by sudden and unexpected vehicle movement do not determine the fluid level until you 1 Put the transmission into N Neutral 2 Apply the parking brake and emergency brakes and make sure they are properly engaged 3 Chock the wheels and take any other steps necessary to keep the vehicle from moving Add transmission fluid to the transmission through the fill tube opening after dipstick calibration is completed Be sure to use proper transmission fluid and fluid containers as discussed in and 2 6 Refer to Table 2 1 for approximate transmission fluid capacity Table 2 1 Transmission Fluid Capacity Application U S E 4 inch 114 mm oil pan 6 inch 152 mm oil pan 7 inch 178 mm oil pan 24 inch 215 mm oil pan Dropbox Does not include external circuits CAUTION Do not overfill the dropbox Overfil
16. remove the drain plug closest to the bottom of the dropbox Drain the fluid and replace the plug Inspect the fluid for contamination 5 Remove the fill tube if it will interfere during transmission removal 6 Disconnect all other hydraulic lines from the transmission and allow them to drain Cover or plug the lines and openings to keep out dirt 3 2 DISCONNECTING CONTROLS CAUTION Use of an impact wrench requires a means to hold the selector shaft to prevent internal damage 1 Disconnect or completely remove all controls from the transmission and position them so they do not interfere with transmission removal NOTE On models with a splined shift selector shaft mark the J transmission shift selector lever with a center punch adjacent to the index mark on the selector shaft before removing the lever if a mark is not already present on the lever Do not use excessive force to remove the lever Failure to work the lever carefully from the shaft will cause internal damage 33 2 Disconnect all linkage or cables for shifting shift modulation hydraulic retarder output disconnect controls parking brake and speedometer Remove the mechanical modulator control For earlier models remove the actuator rod that is free when the modulator is removed refer to 3 Disconnect the power takeoff PTO from its driven equipment Disconnect the PTO controls Remove the PTO if it will interfere with transmission removal 4 Disconnect a
17. 2 Cooler and Filter Connections Without Engine Driven PTO and With Input Retarder 48 ENGINE CONVERTER OUT COVER TEMPERATURE BULB FILTER TO COOLER RR ri FROM F LTER FROM COOLER LEFT S DE RIGHT SIDE vo2380 Figure 6 3 Cooler and Filter Connections Without Engine Driven PTO and Without Input Retarder CONVERTER OUT PTO MOUNT TEMPERATURE BULB TO FILTER ND i FROM FILTER EN ENGINE FROM COOLER ENGINE LEFT SIDE RIGHT SIDE V02388 Figure 6 4 Cooler and Filter Connections With Engine Driven PTO and Without Input Retarder 49 TEMPERATURE BULB PLUG va TO FILTER J ENGINE CONVERTER OUT ENGINE 7 PLUG FROM FILTER CONVERTER INPUT RETARDER HOUSING FROM HOUSING COOL LEFT SIDE RIGHT SIDE vo2390 Figure 6 5 Cooler and Filter Connections With Engine Driven PTO and Input Retarder 1 Connect the external filter and cooler lines to the transmission Avoid kinks sharp bends twists and contact with components that will chafe the hydraulic lines 2 Determine proximity to manifolds or exhaust pipes Excessive heat will hasten the deterioration of hydraulic lines 3 Be sure all lines are proper size and type recommended Use new Viton O ring seals where required Replace any non Viton O r
18. 4 65 Ib ft 73 88 N m Transmission to frame or mounting bolts 164 192 Ib ft 222 260 N m Output flange nut 600 800 Ib ft 813 1085 N m Companion flange or universal joint bolts tighten to vehicle manufacturer s recommendations Manual selector lever nut 15 20 Ib ft 20 27 N m PTO mounting bolts 38 50 Ib ft 52 68 N m Modulator control retaining bolt 15 20 Ib ft 20 27 N m Hydraulic line fittings in transmission housing 40 50 Ib ft 54 68 N m Fill tube nut 90 100 Ib ft 122 136 N m Speedometer body in rear cover 40 50 Ib ft 54 68 N m Speedometer drive cable nut 50 Ib in 6 0 N m Neutral start switch to transmission 50 60 Ib ft 68 81 N m Reverse signal switch to transmission 4 5 Ib ft 5 42 6 78 N m Parking brake bolts to transmission 164 192 Ib ft 222 260 N m Input flange nut 450 550 Ib ft 610 745 N m Fluid temperature sensor 16 20 Ib ft 22 27 N m Fluid Cooler External Filter Lines Inspect for leaks Test for tightness of connections Inspect routing Linkage a Manual selector valve Adjustment at all positions Ease of movement Neutral safety switch start only in neutral Shift selector for freedom of operation b Mechanical modulator control Adjustment Ease of operation Routing c Parking brake Adjust for proper clearance Adjust for full apply Check for full release
19. AA Y TOP OF OIL PAN FILL TUBE HOLE HOT RUN BAND 160 200 F 71 93 C COLD RUN BAND 60 120 F 15 49 C Approximate dimension OEM customer to establish cold run band at installation V02370 pp Figure 2 1 Fluid Level 4 Inch Deep Oil Pan To calibrate the new dipstick strike a mark on the side of the fluid fill tube that has been installed to correspond with the top of transmission oil pan referenced in Figure 2 3 Position the new dipstick down along the outside of the fill tube holding the top even with the top of the fill tube where it would rest if installed into the tube Follow the contour of the fill tube with the dipstick down to the mark previously scribed on the side of the fill tube representing the top of the oil pan Mark the dipstick Now measure down 2 5 inches 64 mm below the top of the pan and scribe a line across the dipstick dipstick may not be vertical This will be the top line of the HOT RUN band as illustrated in Figure 2 3 TOP OF 1 50 in OIL PAN 381 mm EIS dS 052mm 2mm agpi _ HOT RUN BAND 122 2 mm _ 160 200 F 71 93 C gt OIL PAN COLD RUN BAND FILL TUBE HOLE 60 120 F 16 49 C Approximate dimension OEM customer to establish cold run band at installation V02371 Figure 2 2 Fluid Level 6 Inch Deep Oil Pan At a point 1 0 inch 25
20. ARING Section IV TRANSMISSION FOR INSTALLATION INSPECTING FLYWHEEL Bolt Holes 4 2 a Inspect the 12 bolt circle on the front of the flywheel The 20 threads must be undamaged and the holes free of chips or foreign material Inspect the pilot boss at center of flywheel for damage or raised metal that would prevent free entry into the hub adapter Inspect the starter ring gear for excessive wear or damage Check welds that retain the ring gear where applicable Inspect the transmission mounting flange for gasket remnants raised metal or dirt INSTALLING OUTPUT FLANGE OR YOKE Output Oil Seal Inspect the rear oil seal for failure or damage For replacement instructions refer to Service Manual SM1270EN HT 700 Series or SMI314EN CT 700 Series Lubricate the oil seal with high temperature grease or transmission fluid Inspect the output flange or yoke for damage or wear The oil seal contact surface must be smooth and regular to prevent transmission fluid from leaking past the seal Install the parking brake assembly Tighten the bolts to 180 Ib ft 240 N m Install the output flange or yoke Rotate the flange during installation to avoid seal lip damage The brake drum if it mounts ahead of the flange or yoke must be attached before the flange is installed and its bolts tightened to the torque recommended by the vehicle manufacturer Be sure the flange or yoke hub is seated against the transmissio
21. E 3 1 3 2 3 3 3 4 3 5 3 6 3 3 DRAINING TRANSMISSION 33 DISCONNECTING CONTROLS 2 1 wen en Die tees 33 UNCOUPLING FROM DRIVELINE ENGINE AND VEHICLE 34 REMOVING MOUNTING BOLTS 35 REMOVING THE TRANSMISSION 35 REMOVING OUTPUT FLANGE OR YOKE 35 REMOVING OUTPUT FLANGE OR YOKE 35 SECTION IV PREPARING TRANSMISSION FOR INSTALLATION 4 1 4 2 4 3 44 45 4 6 INSPECTING FLYWHEEL asare neu ais aan 36 INSTALLING OUTPUT FLANGE OR YOKE 36 INSTALLING INPUT FLANGE REMOTE MOUNT MODELS 37 INSTALLING SHIFT SELECTOR LEVER 38 INSTALLING POWER TAKEOFF 39 CONNECTING SHIFT MODULATOR CONTROL 40 47 4 8 INSTALLING OIL FILL TUBE cae ex See 40 FRONT MOUNTING SPACERS 41 SECTION V PREPARING VEHICLE FOR TRANSMISSION 5 1 5 2 5 3 5 4 5 5 5 6 INSTALLATION ENGINE TRANSMISSION ADAPTATION REQUIREMENTS 42 INSPECTING FLEXPLATE DRIVE ASSEMBLY ENGINE MOUNTED MODELS 43 INSPECTING INPUT DRIVE COMPONENTS REMOTE MOUNTED MODELS 43 INSPECTING CHASSIS DRIVELINE 43 COOLER FILTER AND LINES 3a 45 0 444545 ae cud 44 INSPECTING CONTROLS 42 eek M RR 432808 e oe
22. FRONT MOUNTING TEMPERATURE SENSOR PORT ON _ gt A COVER ah TRANSMISSION MAIN HOUSING X7 NAMEPLATE gt To COOLER e FROM COOLER REVERSE FILL TUBE PROVISION H02353 Figure 1 1 CLBT 754 Remote Mount Transmission Right Front 10 TO COOLER BREATHER TEMPERATURE SENSOR PORT TRANSMISSION MAIN HOUSING REVERSE TAP PREHEAT a PROVISION FILL TUBE PROVISION FROM COOLER N STARTER RING GEAR FLYWHEEL CONVERTER HOUSING MOUNTING PAD H02356 Figure 1 2 HT 754CR Transmission Right Front BREATHER CONVERTER HOUSING MOUNTING PAD TRANSMISSION MAIN HOUSING STARTER RING GEAR TEMPERATURE SENSOR PORT NAMEPLATE 5 4 REVERSE TAR TO COOLER PREHEAT PROVISION FROM COOLER FILL TUBE INPUT RETARDER PROVISION VALVE BODY Figure 1 3 7500 Transmission Right Front With Input Retarder and Engine driven PTO Provision 1 TO COOLER TEMPERATURE BREATHER SENSOR PORT STARTER TRANSMISSION RING GEAR MAIN HOUSING N FLYWHEEL PREHEAT CONVERTER HOUSING MOUNTING PAD FILL TUBE PROVISION FROM COOLER H2530 Figure 1 4 HT 740 Transmission Right Front 12 HOUSING TRANSMISSION nen RETARDER HOUSING FIRST CLUTCH ADAPTER HOUSING ENGINE DRIVEN TOP POWER TAKEOFF PAD TRANSFER GEAR HOUSI
23. N a Purpose The stall test provides a method for determining if the malfunction is in the engine or in the transmission when the vehicle powerpack is not performing satisfactorily The neutral cool down procedure uses the two minute cooling period on the stall test to gather fluid temperature data for troubleshooting reference 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 If the engine stall speed conforms to specification but the transmission fluid overheats refer to the cool down procedure If the fluid does not cool during the two minute cool down procedure a stuck stator could be indicated If the engine stall speed conforms to specifications and the cool down procedure shows that transmission fluid cools properly refer to the latest version of the troubleshooting manual for further troubleshooting procedures b Transmission Stall Test Procedure The actual engine stall point rpm under load is compared to the established normal speed specified by the engine manufacturer 30 NOTE The engine data for the test is available from the engine manufacturer or from your vehicle dealer or distributor 1 Connect a tachometer of known accuracy to the engine and install a temperature probe into the converter out to cooler line Bring the transmission to the normal operating converter out temperature of 180 220
24. NG DROPBOX FLYWHEEL DROPBOX am ADAPTER DISCONNECT CLUTCH CONVERTER STARTER FILL TUBE HOUSING RING GEAR PROVISION H02361 Figure 1 5 CLBT 754DB Direct Mount Transmission Right Front ENGINE DRIVEN UPPER MANUAL SIDE POWER DISCONNECT CLUTCH TAKEOFF PAD SHIFTER SHAFT 7 INCH OIL PAN TRANSFER GEAR HOUSING DROPBOX LOWER REAR OUTPUT E H02363 Figure 1 6 CLBT 754DB Transmission Left Rear 14 PREVENTIVE MAINTENANCE 2 1 PERIODIC INSPECTION AND CARE Clean and inspect the exterior of the transmission at regular intervals The severity of service and operating conditions will determine the frequency of such inspections Inspect the transmission for loose bolts fluid leaks or damaged or loose hydraulic lines Fluid leaks require immediate attention Modulator cable linkage at the engine fuel lever and shift selector linkage must be kept Clean Properly adjusted Lubricated 2 2 IMPORTANCE OF PROPER TRANSMISSION FLUID LEVEL The transmission fluid cools lubricates and transmits hydraulic power It is important that the proper fluid level be maintained at all times If the fluid level is too low the converter and clutches will not receive an adequate supply of fluid If the level is too high the fluid will aerate the transmission will overheat and fluid may be expelled through the breather or dipstick tube 2 3 AERATED FLUID Aeration chan
25. TALLING SHIFT SELECTOR LEVER Two types of manual shift selector shafts are currently used the flatted type and the splined type a Flatted Selector Shafts 1 For flatted selector shafts install the flatted selector lever onto the selector shaft The flats in the lever will seat on the tapered flats on the selector shaft before the lever seats against the shaft shoulder e CAUTION Flatted selector shafts that are center drilled at their outer ends require an M10 x 1 5 6G nut metric thread Shafts that are undrilled require a 16 nut standard inch series Use of the wrong nut will damage both the shaft and the nut 2 Install the lever retaining nut finger tight against the lever 3 Shift the selector to a position two detent clicks away from either end CAUTION Overtightening the nut can damage the shaft and or lever 4 Hold the lever and tighten the nut to 15 20 Ib ft 20 27 N m refer to Figure 4 1 b Splined Selector Shafts 1 For splined selector shafts loosen the clamp bolt in the shift selector lever 2 Locate the punch mark that was put on the outer side of the lever Paragraph 3 2 when removed 38 SELECTOR LEVER ACTUATOR ROD LATER MODELS RETAINED INTERNALLY 02377 Figure 4 1 Holding Selector Lever For Removal Installation Of Nut 3 Spread the clamp end of the lever and install the lever so that the punch mark aligns with the index mark on the end o
26. a free pin 4 Do the same procedure again except this time begin with the driver s shift selector in the first position 51 5 Start the engine and move the shift selector to D Drive Slowly move the shift selector toward N Neutral Clutch release or engine rpm increase should be felt before the lever reaches the N Neutral slot 6 Move the lever to the R Reverse position then slowly move the shift selector toward N Neutral Clutch release or an engine rpm increase should be felt before the selector reaches the N Neutral slot vehicle service manual and to Preventive Maintenance Oil Field NOTE For installation of dual mode shifting or other options refer to Applications PM1772EN 6 8 CONNECTING HYDRAULIC INPUT RETARDER CONTROL 1 Place the operator s control at the OFF disengaged position 2 Inspect the hydraulic retarder control valve The valve is spring loaded to retract into the valve body when the retarder is OFF Lift the valve upward to the ON position to determine the full travel distance 1 5 inches 38 mm from OFF to ON position 3 Release the valve permitting the spring to retract the valve 4 Adjust the linkage so that the rod end or the clevis registers with the pin hole in the retarder valve Connect the linkage to the retarder valve and inspect the operation of the valve The valve must be fully extended when the operator s control is at ON the valve must be fully retracted when
27. al 180 220 F 82 105 C 2 8 TRANSMISSION FLUID AND FILTER CHANGE INTERVALS Filters to be changed include the following Standard main pressure external filter or high efficiency main pressure external filter Governor filter Suction screen in the oil pan 24 only be changed at transmission overhaul NOTE The governor filter and suction screen in the oil pan should a Transmission Fluid Change CAUTION Transmission fluid and filter change frequency is determined by the severity of transmission service More frequent changes may be necessary than recommended in the general guidelines when operating conditions created high levels of contamination or overheating Table 2 5 is a general guide for fluid and filter change intervals Fluid must be changed whenever there is evidence of dirt or high temperature indicated by discoloration or change in fluid analysis Refer to Table 2 4 for applicable fluid analysis oxidation measurement limits Table 2 4 Fluid Oxidation Measurement Limits Measurement Viscosity 2596 change from new fluid Total Acid Number 3 0 change from new fluid Solids 2 percent by volume maximum mg of potassium hydroxide KOH to neutralize a gram of fluid Transmission protection and fluid change intervals can be optimized by the use of fluid analysis However filters must be changed at or before recommended intervals Consult your local industrial yellow pages for transmissi
28. ater inspect the cooler heat exchanger for leakage between the water and fluid areas Fluid in the water side of the cooler heat exchanger is another sign of leakage This however may indicate leakage from the engine oil system b Metal Particles Metal particles in the transmission fluid or on the magnetic drain plug except for the minute particles normally trapped in the filter indicate damage has occurred in the transmission When these particles are found in the sump the transmission must be disassembled and closely inspected to find the source Metal contamination will require complete disassembly of the transmission and cleaning of all internal and external circuits cooler and all other areas where the particles could lodge During the repair of a major internal failure of a transmission it should be dismantled into as many serviceable detail parts as possible and thoroughly cleaned Do not disassemble the unit just to the problem area 27 c Water Coolant Leakage NOTE Cooler water can be contaminated by engine oil Be sure to J locate the actual source of cooler contamination The presence of ethylene glycol coolant in the transmission fluid is detrimental to the reliability and durability of the internal components Contaminated fluid has a deteriorating effect on transmission components seals gasket etc and on highly loaded steel parts such as bearings and gears due to reduced lubricity of the fluid Fric
29. be handled in clean containers fillers etc to prevent foreign material from entering the transmission Clean around the filler tube before removing the dipstick Lay the dipstick in a clean place while filling the transmission 2 6 AUTOMATIC TRANSMISSION FLUID RECOMMENDATIONS Hydraulic fluids oils used in the transmission are important influences on transmission performance reliability and durability TranSynd or another TES 295 fluid is recommended for all on highway and general applications DEXRON III can also be used in on highway or general applications Type C 4 fluids are recommended for severe duty and off highway applications Some DEXRON III fluids are also qualified as Type C 4 fluids To be sure the fluid is qualified for use in Allison transmissions look for a DEXRON III or C 4 fluid license or approval number 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 and universal farm fluids may or may not be properly qualified for use in your Allison transmission When choosing the optimum viscosity grade of fluid to use the following must be taken into consideration Duty cycle Preheat capabilities Geographical location Table 2 2 lists the minimum fluid temperatures at which the transmission may be safely operated Preheat with auxiliary heating equipment or by running the vehicle wi
30. circuit pressure drop is above specifications the cooler has trapped particles and must be replaced 28 Nelco Company offers a kit that detects the presence of ethylene glycol in transmission fluid The kit is identified as GLY TEK Test Kit and can be obtained from Nelco Company 1047 McKnight Road South Saint Paul MN 55119 651 738 2014 Some conditions that may indicate water and or glycol in the fluid are Rust or pitted transmission parts Transmission fluid spewing out of transmission breather Transmission fluid in radiator Gaskets blistered or wrinkled in uncompressed areas Appearance of fluid presence of water causes a cloudy or gray pink or strawberry colored fluid Steam from the breather For additional field analysis information refer to Allison Transmission publication number GN2055EN Automatic Transmission Fluid Technician s Guide Use this publication to review testing methods and limits of water glycol content 2 10 AUXILIARY FILTER If a condition occurs that introduces debris into the transmission hydraulic system a complete cleanup of the cooler and lines is required Because repeated cleaning and flushing may not remove all debris install an auxiliary filter in the cooler out circuit models without an output retarder or in the lubrication circuit models with an output retarder This recommendation applies whether the transmission is overhauled or replaced by a new or rebuilt un
31. d DEXRON is a registered trademark of the General Motors Corporation Viton is a registered trademark of DuPont Corporation WARNINGS CAUTIONS NOTES IT IS YOUR RESPONSIBILITY to be completely familiar with the warnings and cautions described in this handbook It is however important to understand that these warnings and cautions are not exhaustive Allison Transmission could not possibly know evaluate and advise the service trade of all conceivable ways in which service might be done or of the possible hazardous consequences of each way 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 equipment safety will be jeopardized by the service methods selected Proper service and repair is important to the safe reliable operation of the equipment The service procedures recommended by Allison Transmission and described in this handbook are effective methods for performing service operations Some of these service operations require the use of tools specially designed for the purpose The special tools should be used when and as recommended The following three types of headings are used in this manual to attract your attention WARNING A warning is used when an operating procedure practice etc if not correctly followed could res
32. device is the push type 1 5 in 38 mm EM TRAVEL PLUNGER CAM WEDGE PULL TO OPERATE ILLUSTRATED L02397 Figure 6 8 Earlier Style Mechanical Modulator 8 The conversion of either the lever or cam type to the opposite mode of operation requires the internal parts to be reassembled Reverse the positions of the lever spring and thimble in the lever type to convert it refer to Figure 6 7 Reverse the cam in the cam type to convert it 9 Be sure the modulator control action is as required 10 Install the O ring seal onto the modulator control Coat the O ring with oil soluble grease 11 For earlier models refer to Figure 6 9 install the modulator actuator rod into the modulator valve body through the modulator mounting hole in the transmission housing NEUTRAL START SWITCH LOCATION NA SELECTOR g LEVER SHAFT an ACTUATOR ROD LATER MODELS RETAINED INTERNALLY 02398 Figure 6 9 Connector Locations Left Side CAUTION If the modulator actuator rod is omitted or falls into the pan during modulator installation earlier models the result will be excessive modulator pressure which will cause the lockup clutch to engage and stall the engine 1 N Install the modulator control into the transmission Attach the control housing with the spring clip and the 7 6 18 x inch bolt provided The convex side of the formed end of the clip
33. diameter Limit 0 020 inch 0 51 mm T I R maximum Measure the converter axial location Limits 3 413 3 592 inch 86 69 91 24 mm INSPECTING FLEXPLATE DRIVE ASSEMBLY ENGINE MOUNTED MODELS Inspect the flexplate Replace it if worn or damaged Examine the flexplate for pitting cracks distortion and elongated bolt holes Measure the engine crankshaft end play It must be within the limits prescribed by the engine manufacturer Measure the concentricity of the engine crankshaft hub with the flywheel housing Refer to engine specifications for runout limits Install the flexplate assembly onto the engine crankshaft using the bolts and torque specifications prescribed by the engine or vehicle manufacturer Refer to Figure 3 1 for the proper position of the installed flexplate INSPECTING INPUT DRIVE COMPONENTS REMOTE MOUNTED MODELS Inspect shaft condition The shaft must not be dented or bent Welds must be sound Remove any accumulation of grease and dirt Inspect universal joints yokes coupling flanges and slip joint splines for wear or damage Driveline angles runout or balance which does not conform to the manufacturer s recommendations Lubricate universal joints and slip joints using the vehicle manufacturer s recommendation for lubricants 5 4 Inspect driveline universal joints or slip joints for indexing to conform to vehicle manufacturer s specifications INSPECTING CHASSIS DRIVELINE In
34. e the PTO output to its driven equipment Inspect couplings or universal joints for proper assembly and alignment 6 11 CONNECTING PARKING BRAKE CONTROL Connect and properly adjust the parking brake linkage N Adjust the brake shoe to drum clearance as specified by the manufacturer 6 12 CONNECTING OUTPUT DISCONNECT SHAFT CONTROLS DROPBOX Connect and adjust the output disconnect shaft linkage 2 If a manual actuator is used adjust the linkage to give a crisp detent at the engaged and disengaged positions approximately 1 06 inch 26 9 mm If an air actuator is used the stroke of the cylinder must be controlled to give a crisp detent at the engaged and disengaged positions 4 Be sure there is no force applied to the shifter shaft when in the fully engaged or disengaged position 6 13 CONNECTING SPEEDOMETER DRIVE Install the speedometer driven gear assembly into the transmission Tighten the body in the transmission rear cover to 45 50 Ib ft 61 68 N m If speedometer drive is provided be sure the plug is installed to close the hole in the housing torque is same as for driven gear body 2 Install the speedometer drive cable onto the driven gear assembly Tighten the nut to 50 Ib in 5 65 N m Avoid kinks or sharp bends in the cable assembly All bends must have a radius of 6 inches 150 mm or more No more than one 90 degree bend is allowed 56 6 14 2 3 4
35. e vehicle to determine if the transmission is functioning properly The test drive should include a variety of conditions and terrain that will reveal any deficiency in the transmission operation or need for adjustment Inspect the instruments that are associated with the transmission These include the speedometer and the transmission temperature gauge Apply and release the parking brake Make sure it is not dragging or heating up while the vehicle is traveling Operate the PTO Refer to the Operator s Manual for general operating instructions or to the vehicle manufacturer s specific instructions Determine the no load governed speed of the engine Adjust the governor if necessary to meet the no load governed speed specified for your particular engine transmission match available from vehicle manufacturer Operate the hydraulic input retarder while descending a grade or slowing on a level road Operate a stationary vehicle s input retarder by revving the engine to full no load govern speed in neutral and applying the retarder Note the engine speed will drop significantly To test shift points refer to Service Manual SMI270EN or SM1314EN for proper procedure 59 7 2 INSPECTING FLEXPLATE DRIVE ASSEMBLY ENGINE MOUNTED MODELS Use this list after transmission installation As items are tested or inspected mark them off this list Proper Torque Flexplate bolts 96 115 Ib ft 130 156 N m Transmission to engine bolts 5
36. es in the converter housing with those in the engine flywheel housing Install all of the bolts finger tight that attach the transmission to the engine 46 7 Tighten four bolts at 90 degree intervals around the converter housing bolt circle Then tighten the remaining bolts Use the torque recommended by the vehicle or engine manufacturer oo Remove the guide bolt through the access opening in the engine flywheel housing Replace it with a 20 x 1 inch self locking bolt Tighten the bolt finger tight at this time 9 While rotating the engine crankshaft install the eleven remaining 20 x 1 inch self locking bolts into the flywheel finger tight When all bolts are in place tighten them to 96 115 Ib ft 131 156 N m 10 Install the flywheel housing access cover 6 3 INSTALLING MOUNTING COMPONENTS 1 Install all bolts washers spacers isolators supports or cross members required to support the transmission in the vehicle frame the vehicle manufacturer The g 11 bolts in the converter housing must have at least 32 mm 1 inches thread engagement The 10 bolts in the rear adapter housing must have at least 38 mm 1 inches thread engagement but must not bottom in the adapter housing CAUTION Use the type and grade of mounting bolts recommended by N Tighten the bolts to the torque recommended by the vehicle manufacturer 6 4 COUPLING TO ENGINE REMOTE MOUNTED MODELS Install if remo
37. f the transmission selector shaft Push the lever on the shaft until the splines fully engage To prevent internal damage do not apply excessive force during lever installation 4 Tighten the clamp bolt to 15 20 Ib ft 20 27 N m to attach the lever 4 5 INSTALLING POWER TAKEOFF PTO Space limitation will determine whether the PTO should be installed before or after the transmission is installed The prescribed backlash for turbine and engine driven PTO is 0 006 0 029 inch 0 15 0 74 mm CAUTION Cork or other soft gaskets CANNOT BE USED to mount the PTO Use only shims or gaskets recommended by the PTO manufacturer Establish the proper backlash by selecting the proper thickness shims gaskets when mounting the PTO A PTO that whines is too tight Gear clatter indicates too much backlash too loose 39 To be sure of proper installation locate the PTO unit driven gear before installation immediately behind the transmission drive gear Install two headless guide bolts into the top and bottom of the PTO pad Install the PTO unit Gear backlash can be measured through the inspection port provided in some PTO housings For a PTO mounted at either the top or side of the converter housing the prescribed backlash is in addition to that already provided between the drive gear in the transmission and its driving gear at the rear of the torque converter pump Thus it is necessary to measure the drive gear converter
38. ges the viscosity and color of the transmission fluid to a thin milky liquid and adversely affects transmission performance The primary causes of aeration are Improper fluid Not enough fluid in the sump Too much fluid in the sump defective or missing sealring on the intake pipe of the internal filter Leaking air control system introducing air into transmission A high fluid level too much fluid will cause the clutches to be partially immersed in the sump fluid Rotation of the clutches churns the fluid causing it to become aerated The aerated fluid can also cause overheating 2 4 FLUID LEVEL TEST PROCEDURES possible sudden vehicle movement is avoided Whenever it becomes necessary to leave the vehicle even momentarily while the engine is running place the transmission shift selector in N Neutral set the parking brake and or emergency brakes and chock the wheels 1 WARNING Take the following precautions so that unexpected a Refill After Rebuild Or Overhaul After overhaul or rebuild the system including all external plumbing and components such as filters and heat exchanger must be refilled Dropbox models have to be refilled in both the main transmission section and the dropbox section NOTE The transmission sump and dropbox have independent fluid systems and may require different fluids Refer o Section 26 or the type of fluid Automatic Transmission Fluid Recommendations required in
39. ings External filter replace filter element Filter lines clean and flush inspect for deterioration faulty connectors kinks Refer to Paragraphs 2 9 and 2 101 or additional information 5 6 INSPECTING CONTROLS a Inspection Inspect the transmission control components on the vehicle for the following and correct as necessary Shift selector control for freedom of movement frayed or kinked cables lubrication worn rod ends or clevis pins damaged threads and proper routing Mechanical modulator control for freedom of movement frayed or kinked cables lubrication worn rod ends or clevis pins damaged threads and proper routing Parking brake control for cracks bends damaged threads worn rod ends and clevis pins PTO control for damage wear proper operation and lubrication Hydraulic retarder control for damage wear frayed or kinked cable worn rod ends and clevis pins cotter pins lubrication and proper operation Speedometer drive cable for wear damage kinks lubrication and proper routing Wiring and related electrical components of signals sensors or switches for poor connections frayed wiring and damage Capillary tubes or sensors for temperature gauges Fluid pressure gauge tubing for damage kinks and proper routing 45 6 1 6 2 N INSTALLING Section VI TRANSMISSION INTO VEHICLE HANDLING Handle the transmission carefully to prevent damage to the transmission
40. ings regardless of their condition 4 Tighten the line fittings on the transmission to 50 60 Ib ft 68 81 N m 6 7 CONNECTING SHIFT SELECTOR CONTROL Proper shift selector adjustment is critical Improper linkage adjustment can cause metering of clutch apply fluid resulting in clutch slippage The position of the selector lever refer to directly affects the position of the selector valve When the adjustment is correctly made the linkage to the selector lever retainer pin should move freely When there is no free pin movement it is recommended that the linkage be adjusted as follows 1 At the driver s position place shift lever in the R Reverse position 2 At the transmission rotate the selector lever to the R Reverse position 50 OPT 1 OPT 2 CT 700 SERIES 1 1 2 1 2 2 3 1 3 2 4 14 2 5 1 5 N R INDEXING MARK ON END OF SHAFT LOCATED ON CENTERLINE OF SPLINE TOOTH CT 700 SERIES CENTERDRILL ON SHAFT IDENTIFIES REQUIREMENT FOR METRIC NUT 0 65 WHEN IN Mw NEUTRAL POSITION VERTICAL CENTERLINE FLATS AS SHOWN INDICATE NEUTRAL POSITION 0 65 WHEN IN NEUTRAL POSITION VERTICAL CENTERLINE HT 700 SERIES 02392 Figure 6 6 Shift Selector Positions 3 Align the linkage connector pin to the selector lever Adjust the linkage if necessary to obtain
41. it If any doubt exists about the cleanup of the cooler replace the cooler The auxiliary filter must have at least a 40 micron filter element or finer and a maximum filter pressure drop of 3 psi at 15 gpm 57 liters minute at 180 F 82 C The maximum external circuit pressure drop must not exceed 30 psi 207 at 15 gpm 57 liters minute at operating temperature in drive at full throttle stall The following auxiliary filters are recommended Filter Assembly Filter Element Allison 29510921 Allison 29510918 AC PM 13 16 PF897 29 Purolator OF 15C 1 OF 2C 1 Purolator 20 10 PER 20 High efficiency filter and element are available from your authorized Allison distributor Ref SIL 12 TR 93 latest revision 2 11 BREATHER The breather is located at the top of the transmission housing It serves to prevent pressure buildup within the transmission The breather must be kept clean and the passage open The amount of dust and dirt will determine the frequency at which the breather requires cleaning Use care when cleaning the transmission Spraying steam water and or cleaning solution directly on the breather can force water and cleaning solution into the transmission 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 2 12 TRANSMISSION STALL TEST AND NEUTRAL COOL DOW
42. ks in the pan 2 If the tube is attached by bolts install the oil fill tube and gasket onto the oil pan Install two 5 24 bolts with lockwashers into the oil pan boss to attach the tube assembly Tighten the bolts to 14 18 Ib ft 19 24 N m for 40 models with the 6 7 or 8 inch pan For models with the 4 inch pan tighten the bolts to 26 32 Ib ft 36 44 N m 3 Fasten the upper end of the oil fill tube with brackets and bolts as required 4 Install the dropbox fill tube or fluid level indicator into the dropbox refer to Figure 2 5 4 8 FRONT MOUNTING SPACERS Later transmissions have a reduced width between the mounting pads on the torque converter housing and may require spacers between the mounting pads and vehicle frame mounts SAE grade 8 4 11 1 inch bolts are required nstall two bolts with lockwashers to attach each spacer Tighten the bolts to 164 192 Ib ft 223 260 41 5 1 PREPARING VEHICLE _ Section V FOR TRANSMISSION INSTALLATION Sog ENGINE TRANSMISSION ADAPTATION REQUIREMENTS To adapt the transmission to a new installation be sure that it can be properly coupled to the engine The flexplate assembly and certain engine features must be checked and must be within limits The measuring equipment required includes 24 inch vernier caliper Kent Moore J 26900 25 2 125 3 500 inch telescoping gauge Kent Moore J 26900 25
43. ling can cause excessive fluid temperatures If fluid level is above the FULL line drain fluid as required to bring it to the proper level Clean around the end of the fill tube before removing the dipstick Dirt or foreign matter must not be permitted to enter the transmission because it can cause Valves to stick Undue wear of transmission parts Passages to clog Determine the fluid level by the following procedures and record any abnormal level on your maintenance records Always measure the fluid level at least twice Consistency is important in maintaining accuracy If inconsistent readings persist inspect the transmission breather and the vent hole in the dipstick fill tube to be sure they are clean and free of debris The vent hole is located on the underside of the fill tube just below the seal of the dipstick cap CAUTION The fluid level rises as sump temperature increases DO NOT fill above the COLD RUN band if the transmission fluid is below normal operating temperature An unexplained increase in the amount of sump fluid requires immediate attention A failed rear seal in the engine may be allowing engine oil to enter the transmission sump on wet converter housing transmissions Difference between FULL and ADD levels is 2 U S quarts 1 9 liters HOT RUN BAND 160 200 F 71 93 C 3 50 in 89 9 mm 2 50 in 63 5 mm A 4 75 in Y 120 6 mm
44. must be toward the transmission and against the shoulder of the actuator stem Tighten the bolt to 13 16 Ib ft 18 22 N m 13 Confirm the cable routing Bends must not be of less than 200 mm 8 inches radius Avoid 5 bends The cable must not be nearer than 6 inches 150 mm to the engine exhaust pipe or manifold The cable must follow the movements of the throttle linkage It may be necessary to add a spring to make sure that the movement occurs smoothly 14 Adjust other types of modulator controls as recommended by the vehicle manufacturer 15 The cable routing should avoid proximity with heat source such as exhaust manifolds mufflers tailpipes etc 16 Normal modulator cables will withstand continuous temperatures of 250 F 120 C Insulation heat shields or mechanical linkage actuation may be necessary if 250 F 120 C is exceeded 55 6 10 CONNECTING POWER TAKEOFF PTO CONTROLS 1 If not previously installed mount the PTO on the transmission Refer to Paragraph 4 5 for instructions 2 Connect controls to the PTO Test for proper operation of the controls 3 Inspect cable or linkage rod routing Kinks sharp bends and proximity of the cable to exhaust pipes or manifold must be avoided Rods or linkage must not rub or interfere with adjacent parts CAUTION PTOs using main transmission hydraulic pressure to apply the PTO MUST HAVE main pressure dead headed at the valve when not in use 4 Coupl
45. n rear bearing The output flange or yoke on straight through model transmissions is retained by a large self locking nut This nut may be reused up to five times if it meets running torque requirements during removal refer to Paragraph 3 6 36 Each time the nut is reused deeply scribe one of the wrenching flats This will allow the mechanic to determine how many times the nut has been used Inspect the threads on the output shaft and self locking nut to be sure that they are clean and free of damage To prevent thread galling and inaccurate torque during nut installation apply molybdenum disulfide grease or transmission fluid to the threads of the output shaft and nut flange Failure to hold the flange can cause internal damage to the CAUTION The use of an impact wrench requires a means to hold the 4 3 transmission Install the self locking nut and tighten it to 600 800 Ib ft 814 1085 N m Dropbox models with manual disconnect output clutches use two bolts shims and a locking tab to retain the flange and retainer Refer to Service Manual SM1270EN HT 700 Series or SMI314EN CT 700 Series for shimming procedure and bolt torque If the brake drum mounts behind the flange or yoke install the drum and attach it with bolts or nuts as required Tighten the bolts or nuts to the torque recommended by the vehicle manufacturer INSTALLING INPUT FLANGE REMOTE MOUNT MODELS Inspect the front oil seal for fail
46. nut against the clevis or rod end 4 Confirm the travel of the cable core when the throttle is moved from the fully open to fully closed position The system is designed to provide a minimum travel of 1 187 inch 30 15 mm and a maximum of 1 56 inch 39 6 mm 5 Various kinds of modulator controls may be used but the object of each is to apply increasing force to the modulator actuator rod as the engine fuel control is moved from closed to open position The most common type of control is the cable operated mechanical actuator with a lever to vary the force on the modulator valve The modulator can usually be converted to use either push or pull force on the cable when the throttle is opened Make sure the modulator controls when connected to the throttle linkage provide an increasing force against the modulator actuator rod in the transmission when the engine throttle is moved toward the open throttle position 53 6 Current actuators include a lever that is marked PUSH on one side and PULL on the opposite side When the modulator control cover is removed the word PUSH or PULL can be seen and will indicate how the device is assembled 7 Earlier mechanical actuators include a sliding cam wedge refer to Figure 6 8 When the cover is removed the position of the cam can be seen When the smaller end of the cam is toward the cable housing the device is the pull type When the larger end of the cam is toward the cable housing the
47. nutes to cool the fluid 3 At the end of two minutes record the converter out fluid temperature 31 d Results NOTE Environmental conditions such as ambient temperature J altitude engine accessory loss variations etc affect the power input to the converter Under such conditions a stall speed deviation within a range of 150 rpm from specification can 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 such as need for tune up If engine stall speed is more than 150 rpm above specification a transmission problem is indicated such as slipping clutches cavitation or torque converter failure REMOVING TRANSMISSION FROM VEHICLE 3 1 DRAINING TRANSMISSION Drain the transmission fluid before removing the transmission from the vehicle 1 Park the vehicle on level ground shift to N Neutral and apply the parking or service brake N Start the vehicle engine Operate the engine until the transmission fluid is warm Warm fluid will facilitate quicker and better draining Shut off the vehicle engine and remove the drain plug the transmission oil pan disconnect the fill tube on earlier HT 700 Series models Replace the plug after fluid has drained Examine the drained fluid for evidence of water or debris that indicates failure of internal components 4 On dropbox models
48. ny electrical leads from sensors or other equipment on the transmission 3 3 UNCOUPLING FROM DRIVELINE ENGINE AND VEHICLE 1 Disconnect the vehicle driveline from the transmission output flange or yoke 2 Disconnect the input drive flange or yoke remote mounted 3 Position the propeller shaft to avoid interference with transmission removal 4 Figure 3 1 shows a typical arrangement for coupling the engine and transmission engine mounted FLYWHEEL FLYWHEEL HOUSING STARTER RING GEAR gt i CONVERTER HOUSING J gt lt 3 413 in 86 69 mm 3 592 in 91 24 mm DRIVE BOLT 12 FLEXPLATE ASSEMBLY INNER WEAR PLATE CRANKSHAFT FLEXPLATE TO ADAPTER BOLT a ADAPTER TO CRANKSHAFT BOLT lt lt CRANKSHAFT HUB ADAPTER 02376 Figure 3 1 Typical Transmission To Engine Coupling 34 5 Remove the drive bolts that secure the flexplate assembly to the flywheel 3 4 REMOVING MOUNTING BOLTS If transmission mountings support the rear of the engine place a jack or other support under the engine 2 Support the transmission securely on a jack hoist or other removal equipment Remove all bolts and supports that attach the transmission to engine and vehicle 3 5 REMOVING THE TRANSMISSION 1 Move the transmission away from the engine until completely clear of the
49. on fluid oil analysis firms Use only one analysis firm Results between firms cannot be accurately compared Refer to Allison publication GN2055EN Technician s Guide for Automatic Transmission Fluid for additional information b Standard Main Pressure External Filter Change standard main pressure external filter after the first 5000 miles 8000 km and thereafter as indicated in 25 seuos LH LIN LV U osn Ajuo Kouerogjgo u8TH ISI s1nooo 5 oor posn uooq seu HUN pojeururejuoo SI IAY 1081 INPA e3ueu nun sr o3ueuo ou posn sr Kouerogge u8rq ue UMM x4 SIY 10020 posdej9 savy s noy sqjuour oSeo ru popueururooer Joye esueyD pue Jad dos ouo Jenbo 8891 9J949 TEIIUI opu tod dojs ouo uey 1978918 pue esnjow KEMU3IH YO UO 5 u0 920A 9 x SINOH 0007 SINOH 0002 SINOH 0007 smoH 0001 s noH 0001 SINOH 0007 SUON vc SUON p syuow gr suuonzi sQuoj ZI pc 000 08 000 08 000 091 000 OF 000 OF 000 08 S N 0000 000 0S SOIN 000 001 SON
50. spect the chassis and driveline components for the following conditions and correct as necessary Broken or worn transmission mounts Worn or missing isolators rubber mounts 43 5 5 Improper or damaged bolts hardware Cross frame members rear support members Front mounting spaces some installations have spacers to adapt narrow converter housing mounts to wider mountings on frame Driveline midship or hanger bearings Driveline yoke slip joints for freedom of movement wear lubrication and indexing Driveline angles universal joint indexing runout and balance for conformance to manufacturer s recommendations Auxiliary transmission or transfer case mountings alignment flanges or yokes backlash and fluid leaks PTO driven equipment shafts and couplings for condition and alignment COOLER FILTER AND LINES Inspect the chassis and driveline components for the following conditions and correct as necessary Cooler heat exchanger clean flush or replace if cleaning and flushing are not satisfactory Cooler connecting lines clean and flush inspect for deterioration faulty connectors kinks and leaks lines and fittings for accumulated dirt and grease clean lines and fittings lines for chafing heat deterioration and proper routing replace lines with high temperature lines as required to provide fluid tight systems O rings on fittings replace O rings use Viton O r
51. tart switch If the neutral start switch is not mounted at this location the opening must be plugged The plug seats on a rubber coated washer If so equipped install the reverse signal switch at the right side of the transmission housing Tighten the switch to 48 60 Ib in 5 5 6 7 N m Connect the electrical leads Install and connect other electrical components such as heaters winterization equipment and pressure sensors Install the pressure gauge tubes if so equipped Test the starting circuit The starter should operate only when the transmission shift selector is in the N Neutral position 57 6 15 FILLING THE HYDRAULIC SYSTEM 1 Be sure the hydraulic svstem is properly filled before starting the engine Refer to Section II Preventive Maintenance for capacity information Section II 4c and ot test procedures Section II 4d ind 2 Keep transmission fluid clean 58 7 1 TESTS AND ADJUSTMENTS Section VII ENGINE TRANSMISSION ADAPTATION REQUIREMENTS Refer to Operator s Manual OM1334EN or OM1475EN for instructions Test the neutral start circuit by trying to actuate the starter at all selector positions The starter should operate only when the transmission is in N Neutral Test the position of the operator s selector lever in each drive range and neutral The lever should align with the mark indicating a range or neutral when the transmission is in that range or neutral Drive th
52. th the transmission in neutral for a minimum of 20 minutes before attempting range operation Use only type C 4 Grade SAE 30 transmission fluid in the dropbox 23 Table 2 2 Operating Temperature Requirements for Transmission Fluid Minimum Operating Temperature SAE Viscosity Grade or Fluid Fahrenheit OW 20 Arctic or TranSynd DEXRON III SAE 10W 05 5 SAE 30 303 0 SAE 40 50 ___ SAE W designation means winter weight based on cold temperature properties Arctic as defined by MIL L 46167B Ref SIL 13 TR 90 22 13 15W 40 5 32 50 2 7 FLUID TEMPERATURES If the temperature sensor is located in the converter housing or input retarder valve the critical temperatures are listed in the converter out column If the temperature sensor is located in some other area refer to the vehicle manual for the critical temperatures If the maximum fluid temperature is reached follow this procedure Stop the vehicle and shift the transmission into neutral and operate the engine at 1500 rpm to reduce the transmission fluid temperature If the transmission fluid does not cool in approximately 30 seconds or if it continues to overheat after operation is continued stop the vehicle and engine and locate the problem Converter Out Converter CLBT 700 Series 275 F 135 C max Converter HT 700 Series 300 F 149 C max Retarder Intermittent 330 F 121 C max Lockup 250 F 121 C max Norm
53. the control is at OFF CAUTION Failure to obtain a full OFF stroke will result in low vehicle power and transmission overheating Failure to obtain a full ON stroke will result in less than rated retarder performance no retarder complaint 6 9 CONNECTING MODULATOR CONTROL Connect the engine throttle end of the modulator cable housing to its mounting 2 Open the engine throttle fully and determine whether the throttle linkage will push or pull refer to Figure 67 the cable core when the throttle linkage is moving toward full throttle position If it will push the cable core then push the cable core until it reaches the end of its travel If movement of the throttle linkage toward full throttle position will pull the cable then pull the cable to the end of its travel pa 52 PUSH TYPE V02396 Figure 6 7 Current Mechanical Modulators 3 Adjust the clevis or rod on the cable core until it registers with the hole in the throttle linkage lever and the connecting pin can be freely inserted With the pin removed rotate the clevis or rod end one additional turn counterclockwise viewing cable core from its end for pull type arrangement or one additional turn clockwise for push type arrangement This will make sure that the modulator does not prevent the throttle lever from reaching the full ON position Install the clevis pin or rod end to connect the throttle linkage and cable Tighten the lock
54. the transmission and dropbox The initial running of the engine after overhaul will cause a rapid drawdown of the transmission fluid level Determine the fluid level several times during the first few minutes of operation and add fluid as needed to maintain the level within the COLD RUN band Make an accurate fluid level determination after the fluid level has stabilized and the fluid is hot 160 200 F 71 93 C Refer to Paragraph 2 4c for proper fluid level determination procedures b Fluid Level and Dipstick Figures 2 1 through 2 3 illustrate the fluid levels relative to the 4 6 7 and 8 inch deep oil pans These fluid levels are referenced from the top of the oil pan or the pan to transmission housing splitline NOTE The calibration procedure explained below is applicable to the 7 and 8 inch deep oil pan The same procedure is applicable to the 4 and 6 inch deep oil pan except use the dimensions shown in Figure 2 1 and Figure 2 2 respectively CAUTION The COLD RUN band level Figures 2 1 through 2 4 is an approximate dimension to be established by the OEM Customer at installation An exact HOT RUN band dimension and fluid level should be established prior to the COLD RUN dimension and fluid level A HOT RUN fluid level determine is required for proper operating fluid level 1 00 25 4 mm 1 50 in 38 1 mm 175in 44 5 mm 2 00 in 50 8 mm Y
55. tional capacity of drive clutch plates can be greatly reduced as a result of surface film or impregnation and the presence of glycol will physically deteriorate clutch plate materials If contamination is suspected obtain a fluid sample when the transmission fluid is at normal operating temperature to be sure a contaminant if present is thoroughly dispersed in the fluid being sampled The analysis of the sample by the fluid supplier or any qualified laboratory will provide the degree of contamination and possibly a clue as to its source A minimal amount of water and glycol may be due to one or all of the following Uncovered oil drum Open transmission fill tube Glycol from an all purpose fill container Defective transmission oil cooler Do not use fluid contaminated by water regardless of whether it contains glycol if the water is greater than 0 2 percent by volume of fluid CAUTION If the transmission fluid is contaminated by water 0 2 percent by volume or any trace of ethylene glycol disassemble the transmission and replace the following Seals Gaskets Clutch plates Bearings Torque converter Components that have rusted Solenoids that do not meet resistance specifications Remove all traces of ethylene glycol and varnish deposits Failure to follow this procedure decreases transmission reliability and durability CAUTION After flushing the cooler test the external cooler circuit for restrictions If
56. ult in personal injury or loss of life CAUTION A caution is used when an operating procedure practice etc if not strictly observed could result in damage to or destruction of equipment NOTE A note is used when an operating procedure practice etc is essential to highlight INTRODUCTION 1 1 ABOUT THIS MANUAL This handbook is a mechanic s reference for removing installing and maintaining the HT 700 DB and C LB T 700 DB Series Automatic Transmissions The features of the transmission and vehicle involved in removal and installation procedures are discussed The information presented will help the mechanic to remove install and maintain the transmission in a manner that assures satisfactory operation and long service life Six overall photographs of the HT 700 Series CLBT 700 Series and the CLBT 700 DB Series with transfer gear housing dropbox are on the following pages Each photograph shows the external features and check points discussed throughout this book Use these photos as a reference For additional detailed information refer to HT Service Manual SM1270EN or CL B T 700 Series Service Manual SM1314EN and CLT 750 Preventive Maintenance Oil Field Applications PM1772EN Unless specifically indicated otherwise this handbook refers to all 700 Series on highway transmissions The differences between the various transmissions are explained as required INPUT RETARDER BREATHER VALVE BODY
57. uonrpuoo Po ALON s eAJo1u 12 pue 4 pepueuiuio29H G z 26 c Suction Filter and Governor Filter Change the suction and governor filters located inside the transmission only at overhaul Consult the appropriate service manual for detailed replacement procedure d Fluid and Filter Change Procedure 1 The fluid should be warm when draining This promotes quicker and better drainage N On earlier models remove the fill tube from the oil pan and allow the fluid to drain On later models remove the drain plug from the rear of the oil pan and allow the fluid to drain Examine the condition of the fluid as described in Paragraph 2 9 On earlier models install the filler tube at the side of the pan and tighten the filter tube retainer nut to 90 100 Ib ft 112 136 N m On later models install the oil drain plug at the rear of the oil pan and tighten the plug to 15 20 Ib ft 20 27 N m 4 Remove the dipstick and pour approximately 30 quarts 28 4 liters of transmission fluid into the transmission through the filler tube Then determine the fluid level using the procedure described in Paragraph 2 4 2 9 TRANSMISSION FLUID CONTAMINATION a Examine At Fluid Change At each transmission fluid change examine the fluid that is drained for evidence of dirt or water A normal amount of condensation will emulsify in the fluid during operation of the transmission However if there is evidence of w
58. ure or damage For replacement instructions refer to Service Manual SM1270EN HT 700 Series or SMI314EN CT 700 Series 2 Lubricate the oil seal with high temperature grease or transmission fluid pa Inspect the input flange yoke for damage or wear The oil seal contact surface must be smooth and regular to prevent transmission fluid from leaking past the seal 4 Install the input flange or yoke Rotate the flange during installation to avoid seal lip damage Be sure the flange or yoke is seated against the bearing in the front of the transmission front cover 5 The input flange or yoke is attached by a large self locking nut This nut may be reused up to five times if it meets running torque requirements during removal refer to Paragraph 3 6 6 Each time the nut is reused deeply scribe one of the wrenching flats This will allow the mechanic to determine how many times the nut has been used 37 7 Inspect the threads on the input shaft and self locking nut to be sure they are clean and free of damage To prevent thread galling and inaccurate torque during nut installation apply molybdenum disulfide grease or transmission fluid to the threads of the shaft and nut CAUTION The use of an impact wrench requires a means to hold the flange Failure to hold the flange can cause internal damage to the transmission 8 Install self locking nut and tighten it to 450 550 Ib ft 610 745 N m 4 4 INS
59. ved the input drive shaft components that connect the engine and transmission pa 2 Couple the flange or yoke to the flange or yoke at the front of the transmission Use the bolts and torque recommended by the vehicle manufacturer Compare the alignment of the transmission with the engine against the vehicle manufacturer s specifications 6 5 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 recommended by the vehicle manufacturer N Measure the universal joint angularities all joints in driveline to determine if they are within the specifications of the vehicle manufacturer 47 6 6 CONNECTING COOLER AND FILTER LINES Figure 6 1 through Figure 6 5 illustrate the different filter and cooler connection configurations ENGINE TO FILTER TO COOLER INPUT CONVERTER OUT RETARDER TEMPERATURE BULB HOUSING ADJACENT 6 FROM FROM FILTER PLUG EDER LEFT SIDE RIGHT SIDE V02378 CONVERTER HOUSING Figure 6 1 Earlier Cooler and Filter Connections Without Engine Driven PTO and With Input Retarder 2 BOLT COVER ENGINE PLUG EARLIER MODELS TO FILTER CONVERTER OUT TEMPERATURE BULB Yi L m 4 COOLER FROM FILTER PLUG FROM LEFT SIDE COOLER RIGHT SIDE vo2379 Figure 6
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