Mechanic`s Tips MT(B) 600 Series Transmissions
Contents
1. Chock the wheels and take any other steps necessary to keep the vehicle from moving Warn people to keep clear of the vehicle and its path 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 Run the engine at 1200 1500 rpm in N Neutral for two minutes to cool the transmission fluid between tests If the stall test is repeated do not let the engine overheat 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 temperature of 180 220 F 82 1042 e With the vehicle securely blocked and the parking brake and service brake applied shift to any forward range Then accelerate the engine to wide open throttle and record the maximum rpm the engine will attain This test may also be conducted in R Reverse range if necessary Reduce engine speed to idle and shift to N Neutral mechanisms require the following stall test procedure Put the transmission in the first range hold position Operate the vehicle at maximum speed in first range Apply the vehicle brakes while maintaining f2. Cooler lines to transmission 25 34 1b ft 34 47 N m Temperature sensor plug or temperature sending unit 16 20 lb ft 22 27 N m Fill tube fitting 65 75 Ib ft 88 102 or 90 100 lb ft 122 136 N m with 0 675 inch long oil pan boss Tighten to vehicle manufacturer s specifications 41 PROPER TORQUE cont d Drain plug 15 20 Ib ft 20 27 N m Speedometer driven gear assembly to rear cover 45 50 lb ft 61 68 N m Q Neutral start switch to transmission housing 50 60 16 ft 68 81 N m Reverse signal switch to transmission housing 4 5 1b ft 5 7 N m COOLER AIR AND VACUUM LINES Check for leaks Check for tightness of connections Check routing LINKAGE L Shift selector Adjustment at all positions Ease of movement Neutral safety switch start only in neutral Shift tower for freedom of operation Q Mechanical modulator control Adjustment proper shift points Ease of operation Routing Parking brake Adjust for proper clearance Adjust for full apply Check for full release DRIVELINE Check for proper indexing of universal joints Check for proper drive shaft angles Q Check driveline backlash Lubricate universals and slip joints 42 HYDRAULIC SYSTEM C Recommended fluid refer to Paragraph 1 4 Q Sufficient fluid in transmission Dipstick properly marked
3. Allison Transmission Mechanic s Tips MT B 600 Series Transmissions MT1357EN 1357 Mechanic s Tips Allison Transmission 640 MT 643 MTB 643 R MT 644 MT 647 MTB 647 MT 650 MT 653DR MTB 653DR MT 654CR MTB 654CR Allison July 1997 Transmission Revised 199906 Allison Transmission Inc P O Box 894 Indianapolis Indiana 46206 0894 www allisontransmission com Printed in U S A Copyright 2007 Allison Transmission Inc WARNINGS CAUTIONS AND NOTES ITIS 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
4. Check that retarder only applies at closed throttle Check that the retarder temperature indicator increases rapidly when the retarder is applied C Check that the brake lights come on when the retarder is applied TRANSMISSION FLUID L Fluid level meets specification transmission in N Neutral Check for leaks Warm up transmission and perform a fluid level hot check transmission in N Neutral and vehicle on a level surface OTHER CHECKS Stall check Shift quality Comments 45 CUSTOMER VII SERVICE 7 1 OWNER ASSISTANCE The satisfaction and good will of the owners of Allison transmissions are of primary concern to Allison Transmission Division ATD its distributors and their dealers As an owner of an Allison transmission you have service locations throughout the world that are eager to meet your parts and service needs with e Expert service by trained personnel Emergency service 24 hours day in many areas Complete parts support Sales teams to help determine your requirements e Product information and literature Normally 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 Check the telephone directory for the Allison Transmission service outlet nearest you Reference the Sales and Service Directory SA2229EN fo
5. Fill cap tight Fill tube tight at pan Vent hole in fill tube Breather clean free of restriction Q Filter differential pressure switch and alarm circuit POWER TAKEOFF Q Backlash properly established Q Controls connected and operative Properly coupled to driven equipment Lubrication line properly routed and connected INSTRUMENTS ELECTRIC COMPONENTS Speedometer Q Oil temperature gauge Wiring and electrical connections especially retarder or electric modulator Check neutral start switch MOUNTING No interference between engine transmission components and frame on acceleration Q Rubber mounts free and in good condition Q Tail support preload correct Engine transmission properly aligned Linkages and hoses do not restrain engine roll on acceleration 43 6 2 ROAD TEST AND VEHICLE OPERATION CHECKLIST NEUTRAL START Y Check the position of the operator s selector lever in each drive al range and N Neutral The lever should align with the mark indicating a range or N Neutral when the transmission is in that range or N Neutral Check the neutral safety switch by trying to actuate the starter in every selector position The starter should operate only when the selector lever is in N Neutral position INSTRUMENTS Check the instruments associated with the transmission These include the speedometer and the transmission fluid temperature gauge P
6. SAE 0W 20 Arctic 31 35 DEXRONS III 22 30 SAE 10W 4 20 SAE 15W 40 5 15 5 30 32 0 5 40 50 10 1 7 FLUID AND FILTER CHANGE INTERVALS Fluid and filter change frequencies are determined as follows Table 1 2 is a general guide The fluid must be changed whenever there is evidence of dirt or high temperature indicated by discoloration or strong odor More frequent changes be required when operations are subject to high levels of contamination or overheating e Fluid change intervals can be optimized by monitoring fluid oxidation according to the tests and limits in the Fluid Contamination section of this manual Table 1 2 Fluid and Filter Change Intervals Transmission Internal Sump Governor oe Application Change Filter Filter Filters MT 600 Series 25 000 miles Paper Filter 25 000 miles After first 5000 On Highway 40 000 km 25 000 miles 40 000 km miles 8 000 km Non MT 643R 12 months 40 000 km or 12 months at normal flu 12 months id change inter Stainless Steel vals At overhaul Screen thereafter At overhaul MT 643R After first 5000 Paper Filter 20 000 miles After first 5000 miles 8000 km At every other 32000 km miles 8000 km then at 20 000 fluid change 12 months then at each fluid miles 32 000 Stainless Steel change thereafter km or 12 Screen months At overhaul
7. AUTOMATIC TRANSMISSION FLUID AND VISCOSITY GRADE NON MT 643R TRANSMISSIONS Hydraulic fluids oils used in the transmission are important influences on transmission performance reliability and durability The following transmission fluid and viscosity grades are recommended DEXRONG III fluids for standard duty on highway applications Type C 4 fluids Allison approved SAE 10W or SAE 30 for severe duty and off highway applications Type C 4 SAE 30 for all applications where the ambient temperature is consistently above 95 F 35 C Type C 4 SAE 30 for dropboxes e Some DEXRON III fluids are also qualified as Type C 4 fluids To ensure the fluid is qualified for use in Allison transmissions check for a DEXRONG III or C 4 fluid license or approval numbers on the container or consult the lubricant manufacturer Consult your Allison Transmission dealer or distributor before using other fluid types fluid types such as Type F and universal farm fluids may or may not be properly qualified for use in your Allison transmission CAUTION Disregarding minimum fluid temperature limits can result in transmission malfunction or reduced transmission life When choosing the optimum viscosity grade of fluid to use duty cycle preheat capabilities and or geographical location must be taken into consideration Table 1 1 lists the minimum fluid temperatures at which the transmission may be safely operated in a fo
8. MT 600 Series 1000 hours Paper Filter 1000 hours After first 500 Off Highway maximum 1000 hours maximum hours and at 12 months maximum or 12 12 months normal oil change months intervals Stainless Steel thereafter Screen apply Whichever occurs first Allison high efficiency filter may be used until the Change Filter light indicates it is contaminated or until it has been in use for 3 years whichever occurs first No mileage restrictions A stainless steel screen sump filter is available for all later model MT 600 Series transmissions except the MT B 654CR This filter does not require replacement at the regular fluid change intervals but transmissions equipped with a sump screen must have an auxiliary filter in the external transmission cooling circuit Refer to Service Information Letter SIL 6 TR 96 latest revision 1 8 FLUID AND FILTER CHANGE PROCEDURE a Drain e The transmission should be at operating temperature to assist draining Remove the drain plug from the pan In earlier models without a drain plug remove the fill tube e Examine the drained fluid for evidence of contamination refer to Paragraph 1 9 Remove the pan and gasket Discard the gasket Remove the washer head screw that retains the filter Remove the filter and filter tube Discard the filter if being replaced and the filter tube sealring Clean the pan filter or a 7 0 inch 180 mm pan do
9. RING GEAR ASSEMBLY DRIVE COVER NUTS ACCESSIBLE FROM FRONT I FLEXPLATE CRANKSHAFT PLATE ADAPTER HUB ADAPTER FLEXPLATE CRANKSHAFT CRANKSHAFT CENTERLINE CENTERLINE Figure 2 1 Typical Coupling Methods 640 643 650 653 300 Converter 16 FLYWHEEL HOUSING LOCKWASHER 1 BOLT 12 lt LOCKWASHER 12 BOLT 12 STARTER RING GEAR TRANSMISSION HOUSING BOLT 12 TORQUE CONVERTER PUNP FLEXPLATE CRANKSHAFT HUB ADAPTER ENGINE WEAR PLATE CRANKSHAFT DRIVE COVER 6 CENTERLINE FLYWHEEL LOCKWASHER 10 BOLT 10 TRANSMISSION Vos oes HOUSING SOCKET HEAD SCREW 2 SPACER TORQUE STARTER CONVERTER SAE42 RING PUMP lt CRANKSHAFT FLEXPLATE 3 HUB ADAPTER WEAR PLATE DRIVE COVER Socket head screws gt must be located at BOLT 6 holes nearest to horizontal centerline ENGINE CRANKSHAFT CRANKSHAFT CENTERLINE 03243 Figure 2 2 Typical Coupling Methods 644 647 654CR 400 2 4 REMOVING MOUNTING BOLTS e If transmission mountings support the rear of the engine place a jack or other support under the engine Support the transmission securely on a jack hoist or other removal support equipment Remove all bolts and supports that attach the transmission to the vehicle Refer to Figures 2 1 and
10. ae 5 Fluid and Filter Change 6 Fluid and Filter Change Procedure 8 Fluid Contamination 2 2 2 2 225425554 adie kad aes 9 Auxiliary Filt r 2 tet 10 Breathe 12 Transmission Stall Test and Neutral Cool Down 2 2222 2 2 12 REMOVING TRANSMISSION Draining Transmission 0 000002 eee eee eee 15 Disconnecting 18 15 Uncoupling From Engine And Driveline 16 Removing Mounting 18 Removing Transmission 18 Instructions s soc conan ed ead h 19 PREPARING TRANSMISSION FOR INSTALLATION Checking Input 20 Checking Torque Converter 20 Installing Parking Brake and Output Flange 21 Installing Shift Selector 22 Installing Power Takeoff 23 Installing Shift Modulation Control 25 Installing Fill Tube and Drain Plug 25 Installing Neutral Start and Reverse Signal Switches 26 Checking 2222 222 4 27 ili Paragraph Description Page Section IV PREPARING VEHICLE FOR TRANSMISSION INSTALLATION 4 1 Check
11. cover and transmission housing at the earliest opportunity Remove the spacer if used Figure 2 2 from the engine flywheel housing REPAIR INSTRUCTIONS Refer to the applicable Allison Transmission Service Manual SM1317EN or SM1546EN latest revision to repair the transmission RETAINING STRAP 00014 Figure 2 3 Location of Torque Converter Retaining Strap 19 PREPARING INI TRANSMISSION FOR INSTALLATION 3 1 CHECKING INPUT COMPONENTS Check all bolt holes on the front of the flywheel converter cover flexplate adapter The threads must be undamaged and the holes free of chips or foreign material Check the pilot boss at center of flywheel for damage or raised metal that would prevent free entry into the flexplate hub adapter Check the starter ring gear for excessive wear or damage Check welds that retain the ring gear where applicable Check the transmission mounting flange for gasket remnants raised metal or dirt e Inspect the transmission to engine mounting flange for raised metal burrs and pieces of gasket material Remove any of these defects Inspect the threaded holes for damaged threads 3 2 CHECKING TORQUE CONVERTER POSITION When the transmission is installed the torque converter is axially positioned by the flexplate When properly positioned the torque converter assembly is free of all restraints against fore and aft movement except for that of the
12. flexplate To determine that there will be ample clearance for positioning the torque converter measure as indicated in Figure 3 1 Check the results against the following dimensions 640 643 650 653 2 854 3 014 inch 72 49 76 55 mm MT 644 647 654CR 4 336 4 486 inch 110 14 113 94 mm A measurement outside these dimensions indicates the torque converter is not installed properly Refer to the applicable Allison Transmission Service Manual SM1317EN or SM1546EN latest revision 20 4 336 in 110 14 3 014 in 76 55 mm 4 486 in 113 94 mm 2 854 in 72 49 mm TRANSMISSION TRANSMISSION Measure over HOUSING HOUSING spacer and retainer SPACER FLYWHEEL SPACER AND RETAINER MT 640 643 650 653 MT 644 647 654CR 03244 Figure 3 1 Converter Position Measurements If not previously installed on transmissions coupled as in Figure 2 1 install the flexplate adapter over the spacers and retainers on the drive cover studs Secure the adapter with six nuts tightened to 34 40 16 ft 46 54 N m tensile load of 8000 Ibs 36 KN A nut that meets these requirements NOTE The nuts must be self locking and capable of producing a J is Allison P N 23014107 3 3 INSTALLING PARKING BRAKE AND OUTPUT FLANGE CAUTION Do not attempt to polish the oil seal contact surface on the flange or yoke Scratches or machine type lead can cause sea
13. leaks into the transmission hydraulic system take immediate action to prevent malfunction and possible serious damage Completely disassemble inspect and clean the transmission Remove all traces of the coolant and varnish deposits resulting from coolant contamination Replace friction clutch plates contaminated with ethylene glycol Fluid Analysis Transmission protection and fluid change intervals be optimized by transmission fluid analysis Consult your local telephone directory for fluid analysis firms Use one fluid analysis firm as results from various firms cannot be accurately compared Refer to the Technicians Guide for Automatic Transmission Fluid GN2055EN for additional information To optimize transmission protection the following is the minimum series of tests required to properly monitor the condition of the transmission and transmission fluid filter system e Wear Metals ppm Fe Cu Pb Al e Additive and Contaminant Metals ppm Ba B Ca Mg P Si Na Zn Non metal Contaminants Fuel vol Soot wt Water vol Viscosity cSt at 40 C ASTM D445 Viscosity cSt at 100 C ASTM D445 TAN Total Acid Number ASTM D664 e Particle Counts particles ml at gt 5 gt 10 gt 20 gt 30 and gt 40 microns ppm parts per million cSt centiStokes ml milliliter To optimize fluid change intervals monitor fluid oxidation per the tests and limits shown in Table 1 4 A fluid is
14. mm restriction Usually the restriction is already located in the PTO 3 6 INSTALLING SHIFT MODULATION CONTROL e Install the modulation control after the transmission is put into the vehicle Refer to Paragraphs 5 8 5 9 PTO DRIVE GEAR PTO MOUNTING SNAPRING H00388 02 Figure 3 4 View at PTO Opening 3 7 INSTALLING FILL TUBE AND DRAIN PLUG The fill tube may be installed before the transmission is put into the vehicle unless its presence will interfere with transmission installation e Install the fill tube and tighten the fitting in the pan boss to 65 75 Ib ft 88 102 N m NOTE Torque was increased to 90 100 1b ft 122 136 N m S beginning with S N 2410501058 where the oil pan boss length was changed from 0 575 to 0 675 inch Reference SIL 30 TR 94 25 Fasten the upper end of the fill tube to the engine or transmission with brackets and bolts as required Do not attach the fill tube to the vehicle cab or frame Ensure the drain plug is in place and tightened to 15 20 Ib ft 20 27 N m 3 8 INSTALLING NEUTRAL START AND REVERSE SIGNAL SWITCHES A functional Neutral Start Switch is required to avoid starting the NOTE The type and location of the Neutral Start Switch is optional J engine in range Connect any wiring required for sensors signals switches or other electrical components Install the Neutral Start Switch if so equipped into the tapped open
15. must have a radius of at least 6 inches 152 mm and no more than one 90 degree bend is allowed The torque required to drive the cable and all associated equipment should not exceed 25 oz in 0 17 N m 5 13 FILLING THE TRANSMISSION Be sure the transmission hydraulic system is properly filled with fluid before starting the engine Refer to Paragraph 1 4 40 5 AND SECTION ADJUSTMENTS 6 1 INSTALLATION CHECKLIST PROPER TORQUE q Flexplate to drive cover bolts 41 49 1b ft 56 66 N m Flexplate adapter to drive cover nuts 34 40 1b ft 46 54 N m Transmission to frame mounting bolts Models without retarder 164 192 lb ft 222 260 N m Models with retarder 67 81 1b ft 90 110 N m LJ Converter side mount bolts 81 97 lb ft 110 132 N m Output flange retaining bolt MT 640 643 644 647 102 121 1b ft 138 164 N m q Output flange nut MT 650 653 654CR 600 800 Ib ft 813 1085 N m L Companion flange or universal joints bolts Converter housing adapter to engine housing 54 65 1b ft 73 88 N m Transmission housing to engine housing or adapter 36 43 1b ft 49 58 N m C Manual selector lever nut 15 20 Ib ft 20 27 N m PTO mounting bolts 26 32 1b ft 35 43 N m C Modulator control retaining bolt 10 16 lb ft 14 22 N m Bellcrank and cable support brackets to transmission 42 50 1b ft 57 68 N m
16. not require pan removal Refer to NOTE Transmissions equipped with a stainless steel screen sump J Service Manual SM1317EN or SM1546EN for specific procedures Install a new governor feed filter at the rear of the transmission Refer to the latest revision of Service Manual SM1317EN or SM1546EN for the exact location Install a new filter if required Insert a new sealring onto the filter tube Install the filter tube and filter into the main housing Install the pan and pan gasket if removed Tighten the pan screws to 10 15 1b ft 14 20 NOTE To prevent leakage pan washer head screws must retain J a 5 lb ft 7 N m minimum torque after gasket sets Install the drain plug into the pan and tighten it to 15 20 1b ft 20 27 N m If the fill tube was removed earlier models install the fill tube and tighten the fill tube fitting in the pan boss to the torque shown in Paragraph 6 1 Jf an external auxiliary filter is present replace the filter element Refer to Table 1 2 for replacement intervals b Fill Refill the transmission Refer to Paragraph 1 6 and Table 1 3 The refill amount is less than the initial fill because some of the fluid remains in the external circuits and transmission cavities Check the fluid level as outlined in Paragraph 1 4 Table 1 3 Transmission Fluid Refill Capacities Pan Type Quantity 4 3 inches 110 mm 12 U S qt 11 liters 5 1 inches 130 mm 15
17. on earlier dipsticks coincide J with the HOT RUN band dimension on later dipsticks If desired the dipstick on earlier models can be recalibrated to show HOT RUN and REF FILL COLD RUN 4 34 OIL PAN 5 10 in OIL PAN OIL PAN V03240 Figure 1 1 Typical Dipstick Markings 0 75 1 50 2 22 2 55 19 38 57 65 643 653 03241 Figure 1 2 Fluid Levels Established 1 4 FLUID CHEGK PROCEDURE WARNING To help avoid injury and property damage caused by sudden and unexpected vehicle movement do not perform maintenance or service procedures until you Put the transmission in N Neutral Set the parking brake and service brakes and make sure they are properly engaged Chock the wheels and take any other steps necessary to keep the vehicle from moving CAUTION Dirt or foreign matter must not be permitted to enter the fluid system It can cause valves to stick cause undue wear of transmission parts or clog passages Always check the fluid level a minimum of two times Consistency is important in maintaining accuracy If inconsistent readings persist check the transmission breather and the vent hole in the dipstick fill tube to ensure 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 Check fluid level f
18. only 1 11 BREATHER The breather is located at the top of the transmission housing It serves to prevent pressure buildup within the transmission it must be kept clean and the passage must be kept open The prevalence of dust and dirt will determine the frequency at which the breather requires cleaning Use care when cleaning the transmission Spraying steam water or cleaning solution directly at the breather can force the water or solution into the transmission 1 12 TRANSMISSION STALL TEST AND NEUTRAL COOL DOWN CHECK a Purpose The stall test provides a method for determining if the malfunction is in the engine or in the transmission when a vehicle is not performing satisfactorily neutral cool down check utilizes the two minute cooling period the stall test to gather fluid temperature data for troubleshooting reference manufacturer s data from the engine manufacturer or from your NOTE Before conducting the stall test obtain the engine equipment dealer or distributor b Transmission Stall Test Procedure The engine stall point rpm under load is compared to the engine manufacturer s specified rpm for the stall test WARNING To help avoid injury and property damage caused by sudden and unexpected vehicle movement do not begin a stationary stall test until you e Put the transmission in Neutral Set the parking brake and service brakes and make sure they are properly engaged
19. stall rpm during which the engine does not smoke could indicate a free wheeling torque converter stator If the engine stall speed conforms to specification but the transmission fluid overheats refer to the Neutral Cool Down Check Procedure If the fluid does not cool during the two minute cool down check a stuck torque converter stator could be indicated If the engine stall speed conforms to specification and the cool down check shows that the transmission fluid cools properly refer to the applicable MT Service Manual SM1317EN SM1546EN latest revision for troubleshooting procedures REMOVING SECTION TRANSMISSION II 2 1 DRAINING TRANSMISSION Remove the drain plug from the pan For earlier models disconnect the transmission fill tube from the pan Remove the fill tube completely if it interferes with transmission removal e Examine the drained fluid for evidence of contamination refer to Paragraph 1 9 Install the drain plug and tighten it to 15 20 lb ft 20 27 N m NOTE A significant amount of fluid may drain from the hydraulic J lines when they are disconnected from the transmission Disconnect all hydraulic lines from the transmission Remove the lines from the vehicle if they interfere with transmission removal Cap or plug all hydraulic lines and openings to prevent dirt from entering the hydraulic system 2 2 DISCONNECTING CONTROLS Disconnect the controls from the transmission and positio
20. 2 2 for bolts and nuts within the flywheel housing NOTE To remove the transmission from the flywheel housing do the J following When an adapter is used to adapt the transmission to a larger engine flywheel housing Figure 2 2 remove only the transmission to adapter bolts When a spacer is used the transmission is fastened to the flywheel housing in one of two ways Remove the ten bolts that pass through the spacer and hold the transmission to the flywheel housing To remove the spacer remove the two bolts that hold the spacer to the flywheel housing Remove the ten bolts and two studs that pass through the spacer and hold the transmission to the flywheel housing 2 5 REMOVING TRANSMISSION CAUTION Do not pull the transmission away from the torque converter assembly The torque converter drive cover must be entirely free of any restraint by the flexplate drive or crankshaft pilot when the transmission separates from the engine CAUTION If the spacer is not independently bolted to the engine Figure 2 2 prevent the spacer from falling during transmission removal e Move the transmission rearward until it is clear of the engine Use to prevent the torque converter from separating from the gt transmission Keep the transmission level or the rear slightly low to prevent the torque converter from slipping forward 2 6 Attach retaining strap Figure 2 3 across the converter drive
21. 26 43 31 mm Converter Pilot Hub Diameter 1 699 1 702 in 43 16 43 23 mm Face Squareness 0 0005 in 0 013 mm Pilot EccentricityT MT B 640 643 650 653 S N 33458 and later or models updated with converter pump hub bushing P N 6881926 or roller bearing P N 7455739 all MT B 644 647 654CR MT B 640 643 650 653 prior to S N 33458 0 010 in 0 25 mm T L R 0 005 in 0 13 mm Flexplate Check for Radial Cracks None permitted Check for Elongated Mounting Holes None permitted Check for Any Signs of Distress and or Wear None permitted Mounted Flexplate refer to Figure 4 2 Converter Axial Location 640 643 650 653 Series MT B 644 647 2 854 3 014 in 72 49 76 56 mm 4 336 4 486 in 654CR Series 110 14 113 94 mm Flatness Formed Plates 0 039 in 0 99 mm Flat Plates 0 157 in 3 99 mm per inch of diameter Eccentricity with respect to crankshaft center of rotation A formed flexplate will not be flat but may have raised areas at the bolt holes and or have offset bends in the plate 31 FLYWHEEL HOUSING 2 854 in 72 49 mm 3 014 in 76 55 mm FLEXPLATE RING 543690 693 GEAR ASSEMBLY 4 336 in 110 14 mm 644 647 654CR 786 in 113 94 mm CRANKSHAFT CRANKSHAFT HUB ADAPTER WEAR PLATE 03246 Figure 4 2 Flexplate
22. ARKING BRAKE Check application and release of the parking brake Retarder models do not use a transmission mounted parking brake C Ensure the brake is not dragging or heating up while released C Ensure the brake is fully applied before the lever reaches full travel POWER TAKEOFF PTO Check operation of the PTO Refer to the Operator s Manual OM1334EN for general operating instructions or to the vehicle manufacturer s specific instructions NO LOAD GOVERNED SPEED Check the no load governed speed of the engine Q Adjust the governor if necessary to meet the no load governed speed specified for your particular engine transmission match available from the vehicle manufacturer 44 SHIFT SEQUENCE Check the full load governed speed of the engine Subtract 200 rpm from this speed and record the remainder as the desired speed for all automatic upshifts except the 1 2 shift for the MT 640 643 or 654CR and the 2 3 shift for the MT 650 653 The latter two shifts should occur at full load governed speed less 600 rpm 1 2 shift in MT 650 653 models is a manual shift and not subject to adjustment Drive the vehicle and check the wide open throttle upshift points If adjustment of the shift points is required refer to the applicable MT Service Manual RETARDER Check that the retarder responds correctly C Check that the retarder enable switch turns off the retarder
23. ATOR CONTROL NOTE There are 12V and 24V electric modulators available as of J June 1994 See SIL 27 TR 94 Connect the engine throttle end of the modulator cable housing to its mounting Open the engine throttle fully and check whether the throttle linkage will push or pull 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 e Adjust the clevis or rod end 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 counter clockwise viewing cable core from its end for pull type arrangement or one additional turn clockwise for push type arrangement Install the clevis pin or rod end to connect the throttle linkage and cable Tighten the lock nut against the clevis or rod end This adjustment assures the ability to achieve full throttle on the engine without interference from the modulator control Check the travel of the cable core when the throttle is moved from fully open to fully closed position The system is designed to provide a travel of 1 187 1 560 inches 30 15 39 62 mm The most common type of mechanical control is the cabl
24. Location Dimensions 4 2 CHECKING CHASSIS DRIVELINE Inspect the chassis and driveline and correct any faulty conditions Broken or worn transmission mounts Missing cracked or swollen isolators rubber mounts Improper or damaged bolts or other hardware Permanent deformation of springs in rear transmission support Damaged or worn cross frame members Lack of lubrication excessive end play or wear or deformation of driveline midship or hanger bearings Inadequate freedom of movement wear excessive backlash or lack of lubrication of driveline yoke slip joints Inadequate freedom of movement wear lack of lubrication or damaged needle bearings in universal joints Nonconformance to manufacturer s recommendations for driveline angles universal joint phasing Condition of alignment flanges yokes backlash fluid leaks or torque tightness of mounting bolts for auxiliary transmission or transfer case mountings 32 Excessive backlash in vehicle differential ring gear and pinion refer to the vehicle manufacturer s specifications Damaged condition or improper alignment of PTO driven equipment shafts and couplings 4 3 CHECKING COOLER TUBES HOSES FITTINGS Inspect chassis and transmission related plumbing and correct any faulty conditions Transmission hydraulic system cooler heat exchanger clean and flush or replace if cleaning and flushing are no
25. U S qt 14 liters 7 0 inches 180 mm 17 U S qt 16 liters amount of transmission fluid shown does not include the amount required to fill the external circuits 1 9 FLUID CONTAMINATION a Examine at Fluid Change At each fluid change examine the fluid which is drained for evidence of dirt or engine coolant water A normal amount of condensation will emulsify in the fluid during operation of the transmission However if there is evidence of coolant check the cooler heat exchanger for leakage between the cooler and fluid areas Fluid in the coolant side of the cooler heat exchanger is another sign of leakage This however may indicate leakage from the engine oil system b Metal Particles CAUTION If excessive metal contamination has occurred replacement of the cooler and inspection of all bearings within the transmission is recommended Metal particles in the 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 requires complete disassembly of the transmission and cleaning of all internal and external circuits cooler and all other areas where the particles could lodge Refer to Paragraph 1 10 Auxiliary Filter c Coolant Leakage If engine coolant
26. considered suitable for use if it meets all four limits listed in the table regardless of color or odor If one of the limits is exceeded however the fluid in the subject transmission should be sampled again immediately to verify the exceeded limit If verified the fluid should be changed regardless of time or mileage Table 1 4 Fluid Oxidation Measurement Limits Condition Limit Viscosity 25 Change From New Fluid Carbonyl Absorbance 30 Change From New Fluid Total Acid Number TAN 3 0 Change From New Fluid Solids 2 By Volume Maximum Carbonyl absorbance units em mg of KOH required to neutralize a g of fluid 1 10 AUXILIARY FILTER If a condition occurs that introduces debris into the transmission hydraulic system completely clean up the cooler and lines Because repeated cleaning and flushing not remove all debris installation of an auxiliary filter is recommended This recommendation applies whether the transmission is overhauled or replaced by a new or rebuilt unit For models without a retarder install an auxiliary filter in the cooler out line between the cooler and transmission if such a filter does not already exist For models with an output retarder replace the main cooler and install an auxiliary filter in the line between the retarder control valve and the lube port right side of the transmission For models with an input retarder install an auxiliary filter i
27. dius The cable should not be nearer than 6 inches 15 cm 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 ensure the movement occurs smoothly e Adjust other types of mechanical controls as outlined in the vehicle manufacturer s instructions 5 10 CONNECTING POWER TAKEOFF CONTROLS Ifnot previously installed mount the PTO on the transmission Refer to Paragraph 3 5 for instructions Connect controls to the PTO Check for proper operation of the controls 5 11 CONNECTING PARKING BRAKE CONTROL Install the bellcrank support bracket and cable support brackets onto the transmission housing Tighten the bolts to 42 50 16 ft 57 68 N m Connect and properly adjust the parking brake linkage e Adjust the brake shoe to drum clearance as specified by the manufacturer 5 12 CONNECTING SPEEDOMETER DRIVE Install the speedometer driven gear assembly into the transmission Tighten the body in the transmission rear cover to 45 50 16 ft 61 68 N m If no speedometer drive is provided be sure a steel plug is installed to close the hole in the housing torque is the same as for the driven gear body Do not operate transmission with the plastic shipping plug in this hole Install the speedometer drive cable onto the driven gear assembly Tighten the cable nut to 50 55 Ib in 5 6 6 2 N m Avoid sharp bends in the cable bends
28. e operated actuator with a lever to vary the force on the modulator valve This type of control is convertible either push or pull force can be used on the cable when the throttle is opened Ensure the modulator control when connected to the throttle linkage provides an increasing force against the modulator actuator rod in the transmission when the engine throttle is moved toward the open throttle position Later model actuators include a lever marked PUSH on one side and PULL the opposite side When the modulator control cover is removed the word PUSH or PULL can be seen and indicates how the device is assembled Conversion to the opposite mode of operation is only a matter of reassembling the internal parts Reverse the positions of the lever spring and thimble to convert it Be sure the modulator control action is as required Install the O ring seal onto the modulator control Coat the O ring with oil soluble grease 39 e Install the modulator control into the transmission Install the control housing and secure it with the retainer and the 46 18 3 4 inch bolt provided The convex side of the curved ends of the retainer must be toward the transmission end against the shoulder of the actuator stem Tighten the bolt to 10 16 lb ft 14 22 N m Some mechanical controls include a support bracket also secured by the retainer bolt e Check the cable routing Bends must not be of less than 8 inches 20 cm ra
29. ealer and make of equipment e Transmission model number serial number and assembly number if equipped with electronic controls also provide the ECU assembly number Transmission delivery date and accumulated miles and or hours of operation e Nature of problem Chronological summary of unit s history Step Three If you contacted a regional office and you are still not satisfied present the entire matter to the Home Office by writing to the following address or calling the phone number below Manager Warranty Administration PF9 Allison Transmission P O Box 894 Indianapolis Indiana 46206 0894 Phone 317 242 2052 The inclusion of all pertinent information will assist the Home Office in expediting the matter If an additional review by the Home Office of all the facts involved indicates that some further action can be taken the Regional Office will be advised When contacting the Regional or Home Office please keep in mind that ultimately the problem will likely be resolved at the distributorship or dealership utilizing their facilities equipment and personnel Therefore it is suggested the above steps be followed in sequence when experiencing a problem Your purchase of an Allison Transmission product is greatly appreciated and it is our sincere desire to assure complete satisfaction 47 7 2 SERVICE LITERATURE Additional service literature is available This service literature provides fu
30. ector shaft to a position away from either end position Two detent clicks from either end position is recommended Hold the lever and tighten the nut to 15 20 16 ft 20 27 N m Figure 3 2 The lever must be seated fully against the shaft shoulder 103254 Figure 3 2 Tightening Selector Lever Nut 3 5 INSTALLING POWER PT0 CAUTION Cork or other soft gaskets must never be used to mount the PTO Use only shims or gaskets recommended by the PTO manufacturer Space limitations will determine whether the PTO should be installed before or after the transmission is installed The prescribed backlash between the drive gear in transmission and driven gear in PTO is 0 006 0 029 inch 0 15 0 73 mm or as specified by the PTO manufacturer Early model transmissions have 6 8 pitch drive gear while later models have a 6 pitch gear A 6 pitch or a 6 8 pitch PTO may be used with either gear but the backlash must be maintained e Ifthe PTO has a manual disconnect ensure that the disconnect lever is in the disconnect position before installation The PTO must be installed on the mounting pad with its driven gear to the rear of the PTO drive gear in the transmission Determining PTO Backlash PTO not installed backlash can be measured with special tool J 34814 Figure 3 3 Reference SIL 50 TR 83 and Service Manuals SM1317EN and SM1546EN latest revisions 23 ins
31. es u us ese E quq pu eis 48 PREFACE This handbook is a ready reference for the mechanic removing installing or main taining MT B 600 Series Automatic Transmissions All features of both the vehicle and transmission that become involved in the 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 TRADEMARKS USED DEXRON III is registered trademark of General Motors Corporation Loctite is a registered trademark of the Loctite Corporation Teflon is a registered trademark of the DuPont Corporation 800041 01 Model 643 Transmission Right Front View B00002 01 Model MT 653 Transmission Right Front View Model MTB 644 647 Transmission Right Front View PREVENTIVE SECTION MAINTENANCE I 1 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 the following items Loose bolts transmission and mounting components Fluid leaks correct immediately Shift linkage freely positioned by transmission detent Full and ease of movement of mechanical modulator linkage Leaks in the vacuum or air line and modulator Dama
32. ged or loose fluid lines Worn or frayed electrical connections Worn out of phase driveline U joints and slip fittings Loose or missing speedometer cable and fittings Damaged PTO linkage and driveline Check transmission fluid regularly Once consistent daily hot level checks have been established and daily inspection shows no sign of transmission leakage less frequent checks can be made 1 2 IMPORTANCE OF PROPER FLUID LEVEL Because 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 input pump will draw air into the system and the converter and clutches will not receive an adequate supply of fluid If the level is too high clutch rotation will aerate the fluid the transmission will overheat and fluid may be expelled through the breather or dipstick tube Check the transmission fluid for changes in viscosity or color Thin milky fluid indicates aeration is occurring due to improper fluid incorrect fluid level or a defective or missing sealring on the intake pipe of the internal filter 1 3 DIPSTICK MARKINGS Earlier models use a dipstick marked FULL and ADD Later models use a dipstick marked REF FILL COLD RUN and HOT RUN Figure 1 1 shows typical dipstick markings for MT 600 Series transmissions Figure 1 2 illustrates the marks in relation to the transmission NOTE The ADD and FULL dimensions
33. ified by the vehicle manufacturer 5 6 CONNECTING COOLER VACUUM LINES AIR LINES Connect the lines from the transmission to the cooler forming a transmission fluid to water counterflow in the cooler Vertical mounted coolers require the transmission to cooler line to be connected to the bottom port in the cooler to avoid air locking the cooler 36 5 7 Keep the cooler lines away from exhaust pipes components that cause chafing Avoid kinks and sharp bends The fittings that thread into the transmission housing should be tightened to 25 34 1b ft 34 47 If a vacuum modulator is used connect the vacuum modulator line at the intake manifold If an air modulator is used connect the air line from the junction of the accelerator to engine fuel control air line to the air modulator control Keep the line away from exhaust pipes and components that cause chafing Avoid kinks and sharp bends CONNECTING SHIFT SELECTOR CONTROL Place the operator s shift selector control at the N Neutral position Place the selector lever on the transmission in the N Neutral position Figure 5 1 Adjust the linkage so that it matches full movement of the selector lever on the transmission Connect the linkage to the selector lever Shift through and check all selector positions to ensure the valve body detent positions correspond to the respective selector positions and the selector lever is freely positioned by the transmis
34. ing Flexplate Engine 28 4 2 Checking Chassis Driveline 32 4 3 Checking Cooler Tubes Hoses Fittings 33 4 4 Checking Controls 22 as 33 4 5 Mounting Adapter or Spacer 34 Section V INSTALLING TRANSMISSION INTO VEHICLE 5 1 ee Rae eee aaa eS 35 5 2 Coupling to Engine 35 5 3 Mounting Output 36 5 4 Installing Transmission Mounting Components 36 5 5 Coupling to Driveline 36 5 6 Connecting Cooler Vacuum Lines Air Lines 36 5 7 Connecting Shift Selector 1 37 5 8 Installing Vacuum or Air Modulator Control 38 5 9 Installing Adjusting Mechanical Modulator Control 39 5 10 Connecting Power Takeoff Controls 40 5 11 Connecting Parking Brake 40 5 12 Connecting Speedometer 40 5 13 Filling the Transmission asqa 00 0s 40 Section VI CHECKS AND ADJUSTMENT 6 1 Installation 41 6 2 Road Test and Vehicle Operation Checklist 44 Section VII CUSTOMER SERVICE 7 1 Owner 5 46 7 2 Service Literatur
35. ing above the selector shaft Figure 3 5 The switch must include an aluminum washer gasket approximately 0 090 inch 2 29 mm thick The washer on some switches has indentations on one side Install the washer onto the switch with the indentations facing away from the switch Make sure all mating surfaces are clean and free of contamination Apply a light coat of Loctite pipe sealant with Teflon or equivalent to the threads of the switch Install the switch assembly and tighten it to 50 60 Ib ft 68 81 N m using installation NEUTRAL ae LL 221 ACTUATOR SELECTOR ROD LEVER SHAFT _ 03245 Figure 3 5 Provision for Neutral Start Switch 26 Ifthe Neutral Start Switch is not mounted at this location plug the opening with a 34 16 plug with its head seated a rubber coated washer Apply a light coat of thread sealant onto the threads of the reverse signal switch Install the switch into the 8 inch pipe threaded opening near the nameplate at the right side of the transmission Tighten the switch to 4 5 Ib ft 5 7 Connect the wire leads NOTE An enhanced reverse pressure switch P N 29503665 became ff available in November 1994 The improved switch is stamped with the 3 digit code 484 See SIL 7 TR 95 3 9 CHECKING BREATHER Ensure the breather is clean and free of obstructions Also the breather cap must be loose and free to rattle Figure 3 6 show
36. iption Kent Moore No 1 24 inch 610 mm Vernier caliper J 26900 25 2 1 5 2 inch 38 50 mm telescoping gauge J 26900 23 3 1 2 inch 25 50 mm outside and inside micrometers J 26900 2 4 Dial indicator and attachments base and posts J 5959 01 NI 0 6 inch 0 150 mm depth micrometer set Not offered The 24 inch caliper can also be used as a precision straight edge NI Not illustrated 29 Table 4 1 Measurements Component or Subassembly Required Inspections Limits Flywheel Bore Diameter 17 625 17 630 in Housing 447 68 447 81 mm Bore Eccentricity MT B 640 643 650 653 S N 33458 and later or models updated with converter pump hub bushing P N 6881926 or roller bearing P N 7455739 all MT B 644 647 654CR MT B 640 643 650 653 prior to S N 33458 0 020 in 0 51 mm T I R 0 008 in 0 20 mm T I R Face Squareness MT B 640 643 650 653 S N 33458 and later or models updated with converter pump hub bushing P N 6881926 or roller bearing P N 7455739 all MT B 644 647 654CR MT B 640 643 650 653 prior to S N 33458 0 020 in 0 51 mm T I R 0 008 in 0 20 mm T I R Limits are for installed engines 30 Table 4 1 Measurements Cont d Component Subassembly Required Inspections Limits Crankshaft Hub and or Adapter Crankshaft Hub or Hub Adapter Pilot Diameter 1 703 1 705 43
37. l leakage Check the output flange rear oil seal to ensure that it has not been damaged and is free of defects For replacement instructions refer to the applicable Allison Transmission Service Manual SM1317EN or SM1546EN latest revision Lubricate the oil seal with petrolatum or transmission fluid Check the oil drip tube below the rear cover to ensure it is clean and unobstructed Check the output flange or yoke for damage or wear Check the oil seal contact surface to ensure it is smooth and free of surface irregularities to prevent fluid leaking past the seal Rotate the flange during installation to avoid seal lip damage e Install the parking brake if so equipped 21 CAUTION Do not use hammer or similar tool to install the output flange or yoke onto the transmission output shaft Internal damage can result 6 e Lubricate the splines of the shaft and output flange and install the output flange Ensure the flange hub is seated against the transmission rear bearing The MT 640 643 or 644 647 output flange is retained by a 1 2 20 x 11 2 inch bolt and a washer Replace the bolt and washer each time they are removed Tighten the bolt to 102 121 Ib ft 138 164 N m NOTE Bolt P N 29510838 with improved torque retention should be used This bolt has five grade identification slots in the bolt head rather than the six slots of P N 23014159 Reference SIL 1 TR 94 latest revision The to
38. lly illustrated instructions for the operation maintenance service overhaul and parts support of your transmission To ensure that you get maximum performance and service life from your unit see your dealer or distributor for the following publications Check the telephone directory for the Allison Transmission service outlet nearest you Table 7 1 Service Literature Literature Title L x hee a om Service Manual SM1317EN SM1546EN Parts Catalog PC1316EN PC1551EN Operator s Manual OM1334EN OM1334EN Troubleshooting Manual TS1838EN TS1838EN Automatic Transmission Fluid GN2055EN GN2055EN Technician s Guide Output Retarder Inspection GN2009EN GN2009EN Analysis Also Available On The Internet At www allisontransmission com 48 i h MT1357EN 199701 Rev 1 www allisontransmission com Printed in USA 200603
39. n the secondary cooler circuit CAUTION DO NOT install an auxiliary filter in the MT 643R primary cooler circuit This reduces retarder effectiveness An auxiliary filter in the secondary cooler circuit is sufficient gt Water Flow Flow 2 5 1 SECONDARY COOLER PRIMARY COOLER TYPICAL L03879 02 Figure 1 3 Typical MTR Cooling System If any doubt exists about the cleanup of the cooler replace the cooler Consult your nearest Allison Transmission dealer distributor or the chassis OEM for detailed filter information and availability The auxiliary filter should have a 40 micron or finer filter element and a maximum filter pressure drop of 3 psi 21 kPa at 8 gpm 30 liters minute at 180 F 82 C The maximum external circuit pressure drop at normal operating temperature must not exceed 23 psi 159 kPa for the MT B 640 643 650 653 and 50 psi 345 kPa for the MT B 644 647 654CR at 2000 rpm in N Neutral The following auxiliary filters are recommended Table 1 5 Auxiliary Filter Recommendations Filter Assembly Filter Element Allison 29510923 Allison 29510922 AC PM 13 16 PF 897 AC PM 16 1 PF 141 Fram HP 1 2 HP 1 Purolator OF 15C 1 OF 2C 1 Purolator PER 20 10 PER 20 High efficiency filter and element are available from your authorized Allison distributor Refer to SIL 12 TR 93 latest revision Use with MT 640 643 650 653
40. n them so they Ato do not interfere with transmission removal e Disconnect all linkage or cables for shifting shift modulation parking brake and speedometer Remove the mechanical or electrical modulator control and plug the opening in the transmission e Disconnect the vacuum hose from the vacuum modulator if used Remove the vacuum modulator and plug the opening in the transmission Disconnect the air hose from the air modulator or air operated retarder valve if used Remove the air modulator and plug the opening in the transmission Disconnect the power takeoff from its driven equipment Disconnect controls Remove the PTO completely if it will interfere with transmission removal Cover the PTO opening Disconnect any electrical leads to sensors or other equipment on the transmission 2 3 UNCOUPLING FROM ENGINE AND DRIVELINE e Chock the wheels to prevent the vehicle from rolling ap i e Disconnect the vehicle driveline from the transmission output flange or yoke Position the drive shaft to avoid interference with transmission removal e Figures 2 1 and 2 2 show typical methods of coupling the engine and transmission Remove the drive cover nuts Figure 2 1 or drive bolts Figures 2 1 2 2 FLYWHEEL TRANSMISSION FLYWHEEL TRANSMISSION HOUSING HOUSING HOUS HOUSING FLYWHEEL RING GEAR ASSEMBLY lt DRIVE BOLTS ACCESSIBLE FROM BOTTOM _ 1 FLEXPLATE
41. ollowing procedures record abnormal fluid level milky appearance or any trace of coolant in the fluid on your maintenance records a Cold Check transmission has enough fluid to be safely operated until a Hot Check NOTE The only purpose of the Cold Check is to determine if the J can be made Park the vehicle a level surface set the parking brake and or emergency brakes and chock the vehicle wheels Run the engine at 1000 1500 rpm for one minute to purge air from the system Return engine to idle then shift to D Drive and then to R Reverse to fill the hydraulic circuits with fluid Then shift to N Neutral and allow the engine to idle 500 800 rpm The sump temperature should be between 60 1209 16 499 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 Clean around the end of the fill tube before removing the dipstick Wipe the dipstick clean and check the fluid level If the fluid on the dipstick is within the REF FILL COLD RUN band the level is satisfactory for operating the transmission until the fluid is hot enough to perform a HOT RUN check If the fluid level is not within the REF FILL COLD RUN band add or drain fluid as necessary to bring the level to the middle of the REF FILL COLD RUN band e Perform a hot check at the first opportunity after the normal opera
42. onverter retaining strap when the transmission is in position for installation 5 2 COUPLING TO ENGINE e Align the flexplate and torque converter so that the converter drive 1 4 studs will enter the bolt holes the flexplate Figure 2 1 so that the drive bolts be installed Figures 2 1 2 2 NOTE When the starter ring gear is separate from the flexplate J Figure 2 2 the ring gear must also be aligned Lubricate the center pilot bore and converter nose pilot with molybdenum disulfide grease Push the transmission toward the engine while guiding the pilot boss on the drive cover into the flexplate center bore and the drive studs into the flexplate outer holes Engage the pilot diameter of the transmission housing into the flywheel housing bore If interference is encountered move the transmission away from the engine and investigate the cause Install the SAE Grade 8 bolts that secure the transmission housing to the engine flywheel housing or adapter Tighten the bolts to 36 43 Ib ft 49 58 N m e Install the six drive cover nuts Figure 2 1 or drive bolts Figures 2 1 or 2 2 Tighten each nut or bolt finger tight 35 NOTE drive cover nuts must be self locking capable of producing a tensile load of 8000 lbs 36 A nut that meets these requirements is Allison P N 23014107 e Tighten the drive cover nuts to 34 40 16 ft 46 54 N m e Tighten
43. operations Some of these service operations require the use of tools specially designed for the purpose The special tools should be used when and as recommended Three types of headings are used in this manual to attract your attention These warnings and cautions advise of specific methods or actions that can result in personal injury damage to the equipment or cause the equipment to become unsafe WARNING A warning is used when an operating procedure practice etc if not correctly followed could result in personal injury or loss of life CAUTION A caution is used when an operating procedure 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 Paragraph Section 1 1 1 2 1 3 1 4 1 5 1 6 1 7 1 8 1 9 1 10 1 11 1 12 Section Il 2 4 2 2 923 2 4 2 4 2 6 Section Ill 3 1 3 2 3 3 3 4 3 5 3 6 3 7 3 8 3 9 TABLE OF CONTENTS Description Page PREVENTIVE MAINTENANCE Periodic Inspection 1 Importance of Proper Fluid 1 Dipstick Markings vos ages Bee ads 2 Fluid Check 3 Keeping Fluid Clean 5 Recommended Automatic Transmission Fluid and Viscosity Grade Sa Se
44. r the current listing of Allison Transmission authorized distributors and service dealers We recognize however that despite the best intentions of everyone concerned misunderstandings may occur To further assure your complete satisfaction we have developed the following three step procedure to be followed in the event a problem has not been handled satisfactorily Step One Discuss the problem with a member of management from the distributorship or dealership Frequently complaints are the result of a breakdown in communication and can quickly be resolved by a member of management If you have already discussed the problem with the Sales or Service Manager contact the General Manager All ATD dealers are associated with an ATD distributor If the problem originates with a dealer explain the matter to a management member of the distributorship with whom the dealer has his service agreement The dealer will provide his ATD distributor s name address and telephone number on request 46 Step Two When it appears the problem cannot be resolved readily at the distributor level without additional assistance contact the Allison Transmission Regional Office responsible for the local distributor You will be assisted by a member of the Regional Service Manager s staff depending on the nature of your problem For prompt assistance please have the following information available e Name and location of authorized distributor or d
45. routing NOTE Air pressure input required for pneumatic control is J 55 65 psi 379 448 kPa 33 4 5 Parking brake control cracks bends damaged threads worn ends clevis pins PTO control damage wear improper operation lack of lubrication or improper routing Speedometer drive cable wear damage kinks lack of lubrication improper routing or incorrect drive torque Wiring and related electrical components sensors and switches poor connections frayed wiring or other damage MOUNTING ADAPTER OR SPACER When a mounting adapter Figure 2 2 is used to adapt the transmission to an SAE 1 flywheel housing install the adapter onto the engine Retain it with the twelve SAE Grade 8 bolts and lockwashers supplied with the vehicle Tighten the bolts to 54 65 1b ft 73 88 N m When a mounting spacer is used Figure 2 2 install the spacer onto the engine Retain with the two bolts and washers supplied with the vehicle CAUTION Bolt heads must be below the rear surface of the spacer before installing the transmission 34 INSTALLING SECTION TRANSMISSION INTO VEHICLE 5 1 HANDLING CAUTION The transmission must be handled very carefully after the torque converter retaining strap is removed to avoid separating the torque converter from the transmission Keep the transmission level or the rear slightly lower than the front at all times Remove the torque c
46. rque value is the same for both bolts lt MT B 650 653 or 654CR output flange is retained by a self locking nut Clean the threads of the nut and the output shaft Apply molybdenum disulfide grease to the output shaft and nut threads Install the nut on the output shaft Tighten the nut to 600 800 Ib ft 813 1085 N m NOTE The self locking ability of the nut is reduced with each usage Each time the nut is reused scribe a deep mark on one of the flats on the nut Discard the nut after it has been reused five times 3 4 INSTALLING SHIFT SELECTOR LEVER CAUTION Manual 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 38 16 nut standard inch series Use of the 6 wrong nut will damage both the shaft and nut Torque for either nut is 15 20 lb ft 20 27 N m Excessive torque applied to the nut without holding the lever can damage the internal lever Do not use an impact wrench e Install the selector lever onto the selector shaft The flats in the lever slot interfere slightly with the tapered flats on the selector shaft before the lever seats against the shaft shoulder If such an interference fit is not present replace the selector lever CAUTION Overtightening the lever retaining nut can damage the shaft thread e Install the lever retaining nut finger tight against the lever 22 Shift the sel
47. rward or reverse range Operation at ambient temperatures lower than those shown will require preheating with auxiliary heating equipment or by running the vehicle with the transmission in N Neutral for a minimum of 20 minutes before attempting range operation RECOMMENDED AUTOMATIC TRANSMISSION FLUID AND VISCOSITY GRADE MT 643R TRANSMISSIONS Due to the added heat load from the input retarder MT 643R transmissions require special fluid considerations The approved fluids list is more restrictive than for non retarder MT 643R transmissions Also the fluid change intervals are shorter than for non retarder MT 643R transmissions Only high quality heavy duty diesel engine oils that are approved Allison C 4 fluids with a viscosity of either SAE 30 or SAE 15W 40 are recommended for use in MT 643R transmissions For specific name brands contact the local Allison Transmission Regional Office Refer to Table 1 1 for minimum fluid temperatures at which the transmission may be safely operated with various fluids Operation at ambient temperatures lower than those shown will require preheating with auxiliary heating equipment or by running the vehicle with the transmission in Neutral for a minimum of 20 minutes before attempting range operation Table 1 1 Transmission Fluid Operating Temperature Requirements eee Ambient Temperature Below Which Preheat Viscosity Grade Is Required Fahrenheit Celsius
48. s the breather configurations The earlier breathers should be equipped with a neoprene shroud P N 6883025 Later models have a breather with an integral shroud If the breather shroud is damaged install a new shroud NEOPRENE SHROUD EARLIER MODELS LATER MODELS 02884 Figure 3 6 Breather Configurations 27 SECTION PREPARING VEHICLE IV FOR TRANSMISSION INSTALLATION 4 1 CHECKING FLEXPLATE ENGINE FEATURES Transmission performance may be adversely affected by improper tolerances existing between engine to transmission mating components The drive connection between the engine and transmission converter must transmit engine power properly locate and pilot the torque converter and aid in controlling the forward thrust of the converter Vibration converter section fluid leaks a worn front bushing or bearing and or a worn engine crankshaft thrust bearing are frequently the result of exceeding recommended tolerances in engine to transmission mating components When these conditions are encountered certain important measurements should be investigated before installing a repaired or new transmission These measurements are summarized in Table 4 1 Figure 4 1 illustrates the tooling required for these measurements Refer to SIL 60 TR 81 latest revision 28 00389 01 Figure 4 1 Tooling Used to Determine the Adaptation Measurements of an MT B 600 Series Transmission Tool Descr
49. sion detent 7 an gt 7 2 O 1 1 lt I 1 I K I 1 1 2 2 ae R MT 640 643 644 647 MT 650 653 R MT654CR 1 2 3 4 5 103247 Figure 5 1 Shift Selector Positions 37 5 8 INSTALLING VACUUM OR AIR MODULATOR CONTROL NOTE There are 12V and 24V electric modulators available as of J June 1994 Refer to SIL 27 TR 94 Make sure the original sealring has been removed from the modulator can or from the counterbore of the transmission housing Install the sealring onto the modulator Coat the sealring with oil soluble grease Install the modulator control into the transmission housing Seat the sealring in the counterbore in the housing e Install the modulator retainer so that the convex side of the curved ends are toward the transmission Secure the retainer with 516 18 x 3 4 inch bolt Earlier models use a 516 18 x 6 inch bolt Tighten the bolt to 10 16 lb ft 14 22 N m e Connect the vacuum or air line to the modulator The tube connection at the vacuum modulator should face toward the engine The routing should be approximately 10 degrees below horizontal and include a condensate trap goose neck as shown in Figure 5 2 Jo 10 MODULATOR V03248 HOSE Figure 5 2 Proper Relation of Vacuum Hose to Modulator Control 38 5 9 INSTALLING ADJUSTING MECHANICAL MODUL
50. t satisfactory Cooler connecting lines clean and flush inspect for deterioration leaks faulty connectors kinks Minimum tube size required for cooler circuit is 0 625 inch 15 9 mm or No 12 hose size However a larger hose may be required to meet flow and pressure drop requirements Pay particular attention to any hose with a Teflon liner for inner tube kinks or bubbles Ifthe hydraulic system has been contaminated with debris install an auxiliary filter between the cooler and transmission in cooler return line Refer to Paragraph 1 10 for filter recommendation and installation details Vacuum or air modulator line and or hose inspect for deterioration bad connections loose or missing clamps or improper routing that causes kinks 4 4 CHECKING CONTROLS Inspect transmission control components on vehicle and correct any faulty conditions Shift selector control inadequate freedom of movement frayed or kinked cables lack of lubrication worn rod ends or clevis pins damaged threads or improper routing Mechanical modulator control inadequate freedom of movement frayed kinked cables lack of lubrication worn rod ends or clevis pins damaged threads or improper routing Air modulator control inadequate freedom of movement incorrect pressure calibration engine throttle must go to full throttle position when treadle is fully depressed damaged hoses or fittings or improper
51. talled measure through the inspection port if provided with a dial indicator On PTO units with no inspection port rotate the PTO shaft back and forth Rattling gears indicate too much backlash and require the removal of one or more gaskets from beneath the PTO housing Difficult engagement or whining gears indicate a tight fit and require the addition of one or more gaskets NOTE Do not remove all gaskets from beneath the PTO housing J One gasket minimum is required to prevent fluid leakage Install the PTO unit and gasket s flush to the mounting pad do not force Avoid bumping the snapring Figure 3 4 which could be displaced Secure the PTO with six mounting bolts tighten to 26 32 Ib ft 35 43 N m TRANSMISSION MAIN CASE BASE PLATE GAUGE PIN HOLD DOWN BOLT i reer PTO DRIVE L GEAR V02394 MEASUREMENT PTO PAD Measurement Correction 0 011 0 045 in 0 27 1 16 mm 0 030 Gasket one 0 76 mm Gasket 0 047 0 070 in 1 19 1 78 mm Two 0 030 Gaskets two 0 76 mm Gaskets Figure 3 3 Measuring Turbine Driven PTO Backlash On PTO assemblies that require pressure lubrication install the lubrication tube and fittings The lubricating fluid comes from the line returning to the transmission from the cooler Fluid should be directed to the PTO lubrication 24 circuit after passing through a 0 032 inch 0 81
52. the drive cover bolts to 41 49 1b ft 56 66 N m Check crankshaft end play against engine manufacturer s specifications 5 3 MOUNTING OUTPUT RETARDER Transmissions with the integral output retarder require special attention when mounting The additional weight of the retarder makes it necessary to support the transmission behind the engine using the rear support pads on the top of the retarder housing or the vertical pads on the rear face of the retarder case The converter housing side mount pads cannot be used with MTB 653 direct mount units Only remote mount units and MTB 643 direct mount units may be installed using the side mount pad on the converter housing with a rear support 5 4 INSTALLING TRANSMISSION MOUNTING COMPONENTS CAUTION Y Bolts must not penetrate the two rear holes of the converter side mounting pad more than 1 125 inch 28 6 mm Tighten mounting pad bolts to 81 97 1b ft 110 132 N m Bolts must not penetrate the two front holes of the converter side mounting pad more than 1 25 inch 31 8 mm to avoid interference with the converter Tighten mounting pad bolts to 81 97 1b ft 110 132 N m Install all bolts washers cross members supports and isolators required to support the transmission in the vehicle frame 5 5 COUPLING TO DRIVELINE Couple the driveline companion flange or universal joint yoke to the transmission output flange or yoke e Use the bolts nuts and torque spec
53. ting sump temperature 160 200 F 71 93 C is reached b Hot Check an accurate check operate the transmission until the sump fluid temperature is 160 200 F 71 939 or converter out temperature is 180 220 F 82 104 NOTE The fluid level rises as the temperature increases To ensure Park the vehicle on a level surface and shift to N Neutral Set the parking brake and or emergency brakes and chock the vehicle wheels Allow the engine to idle 500 800 rpm Clean around the end of the fill tube before removing the dipstick Wipe the dipstick clean and check the fluid level The safe operating range is any level within the HOT RUN band on 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 1 5 KEEPING FLUID CLEAN CAUTION Containers or fillers that have been used to handle any antifreeze or engine coolant solution must not be used for transmission fluid Antifreeze and coolant solutions contain ethylene glycol which if introduced into the transmission can cause the clutch plates to fail It is absolutely necessary that the fluid put into the transmission be clean Fluid must be handled in clean containers fillers etc to prevent foreign material from entering the transmission Lay dipstick in a clean place while filling the transmission 1 6 RECOMMENDED AUTOMATIC TRANSMISSION FLUID AND VISCOSITY GRADE RECOMMENDED
54. ull throttle As soon as the vehicle is completely stopped read the engine rpm stall speed from the tachometer Reduce engine speed to idle and shift to N Neutral Increase engine speed to cool the torque converter NOTE Engines having smoke controls throttle delay c Neutral Cool Down Check Procedure The neutral cool down check determines if the transmission fluid cools following an engine load condition Perform this check immediately after the engine speed has been recorded in the stall test Record the converter out fluid temperature e With the transmission remaining in N Neutral run the engine at 1200 1500 rpm for two minutes to cool the fluid At the end of two minutes record the converter out fluid temperature d Results altitude engine accessory loss variations etc affect the power input to the converter Under such conditions a stall speed deviation up to 150 rpm from specification can be accepted as within normal range j NOTE Environmental conditions such as ambient temperature If the engine stall speed is more than 150 rpm below the stall speed specified by the engine manufacturer an engine problem is indicated such as the need for a tune up If the engine stall speed is more than 150 rpm above specification a transmission problem is indicated such as slipping clutches cavitation or torque converter failure An extremely low stall speed such as 33 percent of the specified engine
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