- Allison Transmissions
Contents
1. Be sure that the hose from the main pressure tap on the left side of the transmission is connected to the fitting on the retarder valve body and that connections are tightened Be sure that the short hose from the retarder valve body to the To Cooler port is connected and that connections are tightened 23 3 10 CHECKING BREATHER Ensure the breather is clean and free of obstructions Also the breather cap must be loose and free to rattle Figure 3 5 shows the two 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 V02884 Figure 3 5 Breather Configurations 24 PREPARING VEHICLE SECTION FOR TRANSMISSION IV 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 t2. on acceleration 6 2 ROAD TEST AND VEHICLE OPERATION CHECKLIST e NEUTRAL START N O Check the position of the operator s selector lever in each drive Z range and N Neutral The lever should align with the mark indicating a range or N Neutral or P Park when the transmission is in that range or N Neutral or P Park L 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 or P Park INSTRUMENTS O Check the instruments associated with the transmission These include the speedometer and the transmission oil temperature gauge PARKING BRAKE C Check application and release of the parking brake Q Ensure the brake is not dragging or heating up while released Q Ensure the brake is fully applied before the lever reaches full travel POWER TAKEOFF PTO O 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 U Check the no load governed speed of the engine L Adjust the governor if necessary to meet the no load governed speed specified for your particular engine transmission match available from the vehicle manufacturer 40 SHIFT SEQUENCE U Drive the vehicle and check the wide open throttle upshift points If adjustment of the shift point
3. 2 875 in 68 96 73 03 mm 0 039 in 0 99 mm 0 157 in 3 99 mm Limits are for installed engines T I R per inch of diameter Eccentricity with respect to crankshaft center of rotation Tt A formed flexplate will not be flat but may have raised areas at the bolt holes and or have offset bends in the plate 26 4 2 CHECKING CHASSIS DRIVELINE Inspect the chassis and driveline and correct any faulty conditions 4 3 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 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 and universal joint phasing Condition of alignment flanges yokes backlash fluid leaks or torque tightness of mounting bolts for auxiliary transmission or transfer case mountings Excessive backlash in vehicle differential ring gear and pinion refer to the vehicle manufacturer s specifications Damaged condition or improper alignment of PTO driven equipm
4. Fluid Oxidation Measurement Limits Measurement Limit Viscosity 25 change from new fluid Carbonyl absorbance 0 3 A 0 1 mm change from new fluid Total acid number 3 0 change from new fluid Solids 2 by volume maximum A Absorbance units 1 10 AUXILIARY FILTER If a condition occurs that introduces debris into the transmission hydraulic system a complete cleanup of the cooler and lines is recommended Because repeated cleaning and flushing may not remove all debris installation of an auxiliary filter in the cooler out line between cooler and transmission is recommended This recommendation applies whether the transmission is overhauled or replaced by a new or rebuilt unit CAUTION DO NOT install an auxiliary filter in the AT 500R primary cooler circuit This reduces retarder effectiveness An auxiliary filter in the secondary cooler circuit is sufficient If any doubt exists about the cleanup of the cooler replace the cooler The auxiliary filter should have at least a 40 micron filter element or finer and a maximum filter pressure drop of 3 psi 21 kPa at 4 5 gpm 17 liters minute at 180 F 82 C The maximum external circuit pressure drop must not exceed 35 psi 241 kPa at 4 5 gpm 17 liters minute at operating temperature in N Neutral and at 2400 rpm The following auxiliary filters are recommended Table 1 5 Auxiliary Filter Recommendations Filter Assembly Filter Eleme
5. 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 ir Figure 5 2 Lu TRAP Figure 5 2 Proper Relation of Vacuum Hose to Modulator Control VACUUM MODULATOR V03009 31 5 6 CONNECTING COOLER VACUUM LINES AIR LINES e Connectthe 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 NOTE On retarder units there are two coolers to connect See Figure J 5 3 for proper location of cooler connections Tighten cooler fittings on the primary cooler to 40 50 Ib ft 54 68 N m Tighten cooler fittings on the secondary cooler to 15 22 Ib ft 20 30 N m Keep the lines away from exhaust pipes and components that cause chafing Avoid kinks and sharp bends Tighten the cooler SAE No 8 line fittings that thread into the transmission housing to 15 22 Ib ft 20 30 N m If a vacuum modulator is used connect the vacuum modulator line at the intake manifold If an air modulator is used connect the air modulator control line at the control 5 7 CONNECTING RETARDER CONTROLS e Connect the wiri
6. Neutral safety switch start only in neutral Shift tower for freedom of operation O Mechanical modulator control Adjustment proper shift points Ease of operation Routing Q Parking brake Adjust for proper clearance Adjust for full apply Check for full release 38 DRIVELINE U Check for proper indexing of universal joints U Check for proper drive shaft angles U Check driveline backlash Q Lubricate universals and slip joints HYDRAULIC SYSTEM L Recommended fluid refer to Paragraph 1 6 Q Sufficient fluid in transmissior refer to Paragraph 1 4 O Dipstick properly marked Q Fill cap tight Q Fill tube tight at pan Q Breather clean free of restriction Q Filter differential pressure switch and alarm circuit POWER TAKEOFF Q Backlash properly established Q Controls connected and operative Q Properly coupled to driven equipment C Lubrication line properly routed and connected INSTRUMENTS ELECTRIC COMPONENTS C Speedometer Q Fluid temperature gauge C Wiring and electrical connections especially retarder or electric modulator Q Check neutral start switch e MOUNTING Q No interference between engine transmission components and frame on acceleration U Rubber mounts free and in good condition 39 e MOUNTING cont d Q Tail support preload correct Q Engine transmission properly aligned Q Linkages and hoses do not restrain engine roll
7. bolts 26 32 lb ft 35 43 N m Q Modulator control retaining bolt 10 16 Ib ft 14 22 N m U Parking brake mounting bolts 81 97 Ib ft 110 132 N m B Bellcrank and cable support brackets to transmission 42 49 Ib ft 57 67 N m O Hydraulic line fittings in transmission housing or retarder valve body 15 22 Ib ft 20 30 N m B Primary cooler fittings in retarder valve body 40 50 Ib ft 54 68 N m L Fill tube fitting 65 75 Ib ft 88 102 N m or 90 100 Ib ft 122 136 N m with 0 675 inch long oil pan boss U Drain plug 15 20 Ib ft 20 27 N m U Speedometer driven gear assembly to rear cover 45 50 Ib ft 61 68 N m Tighten to vehicle manufacturer s specifications 37 PROPER TORQUE cont d LJ Neutral start switch to transmission housing 50 60 Ib ft 68 81 N m Q Reverse signal switch to transmission housing 4 5 Ib ft 5 7 N m L Modulator retaining bolt 10 16 Ib ft 14 22 N m B Retarder low speed cutoff switch in transmission housing 4 5 Ib ft 5 7 N m Q Retarder temperature sensor fitting in retarder valve body 15 20 Ib ft 22 27 N m Q Retarder main pressure tap fitting in transmission housing and in retarder valve body 4 5 Ib ft 5 7 N m COOLER AIR AND VACUUM LINES L Check for leaks C Check for tightness of connections Q Check routing LINKAGE O Shift selector Adjustment at all positions Ease of movement
8. 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 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 COLD RUN band add or drain fluid as necessary to bring the level to the middle of the COLD RUN band Perform a hot check at the first opportunity after the normal operating 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 93 C converter out temperature is 180 220 F 82 104 C l NOTE The fluid level rises as the temperature increases To ensure Park the vehicle on a level surface and shift to N Neutral or P Park Set the parking brake and or emergency brakes and chock the vehicle wheels Allow the engine to idle 500 800 rpm 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 Approximately 1 quart 1 liter of fluid is required to raise the level from the bottom to the top of the band 1 5 KEEPING FLUID CLEAN CAUTION Containers or fillers that have been used to handle any antifreeze or engine cool
9. Mechanic s Tips AT 500 and AT 1500 Series Transmissions MT1321EN MT1321EN Mechanic s Tips Allison Transmission AT 540 AT 543 AT 542 AT 542N AT 542R AT 542NR AT 545 AT 545N AT 545R AT 545NR AT 542NFE AT 1542 AT 1542P AT 1542NP AT 1545 AT 1545P AT 1545NP June 1996 Revision 1 1999 April Printed in U S A Copyright 1996 General Motors Corp WARNINGS CAUTIONS AND NOTES IT ISYOUR 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 T
10. OVER CRANKSHAFT WEAR PLATE 71500 AT 540 AT 545 CONVERTER AH on PLATE t d WEAR PLATE i AT 543 mi CONVERTER m DRIVE COVER ETERO A GEAR Seer TRANSMISSION HOUSING DRIVE COVER NUT SAE 2 SAE 3 TO FLYWHEEL HOUSING SAE 2 ADAPTER V03006 Figure 2 1 Typical Coupling Methods 2 4 REMOVING MOUNTING BOLTS 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 engine flywheel housing Figure 2 1 remove only the transmission NOTE When an adapter is used to adapt the transmission to a larger J to adapter bolts e Remove the 10 or 12 bolts that attach the transmission to the engine or adapter 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 Move the transmission rearward until it is clear of the engine Use care to prevent the torque converter from separating from the ue transmission Keep the transmission level or the rear slightly low to prevent the torque converter from slipping forward Remove the adapter ring if used Attach a retaining strap Figure 2 2 across the converter drive cover and transmission housin
11. SION MOUNTING COMPONENTS CAUTION For AT 540 AT 542 Series AT 545 Series and AT 1500 Series mounting pad bolts must penetrate the holes of the mounting pads 1 24 1 39 inch 31 2 35 5 mm Tighten mounting pad bolts to 164 192 Ib ft 222 260 N m For AT 543 mounting pad bolts must penetrate the holes of the mounting pad 0 775 0 900 inch 19 69 22 86 mm Tighten mounting pad bolts to 164 192 Ib ft 222 260 N m Install all bolts washers cross members supports and insulators required to support the transmission in the vehicle frame 30 5 4 COUPLING TO DRIVELINE e Couple the driveline companion flange or universal joint yoke to the transmission output flange or yoke e Use the bolts nuts and torque specified by the vehicle manufacturer 5 5 INSTALLING VACUUM OR AIR MODULATOR CONTROL NOTE There are 12V and 24V electric modulators available as of J June 1994 See SIL 27 TR 94 e 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 nstall the modulator retainer so that the convex side of the curved ends are toward the transmission Secure the retainer with a 546 18 x inch bolt Tighten the bolt to 10 16 Ib ft 19 22
12. The dealer will provide his ATD distributor s name address and telephone number on request 42 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 dealer e Type and make of equipment e Transmission model number serial number and assembly number if equipped with electronic controls also provide the ECU assembly number e Transmission delivery date and accumulated miles and or hours of operation e Nature of problem e 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 3538 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 co
13. ain plug into the pan and tighten it to 15 20 Ib ft 20 27 N m If removed install the fill tube and tighten the fill tube fitting in the pan boss to 65 75 1b ft 88 102 N m If an external auxiliary filter is present replace the filter element Table 1 2 for replacement intervals b Fill Refill the transmission Refer to Paragraph 1 6 and to 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 Shallow pan 3 8 inches 97 mm 9 U S qt 8 5 liters Deep pan 5 3 inches 135 mm 16 U S qt 15 liters The amount of transmission fluid shown in the following chart 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 I
14. ansmission 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 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 AT Service Manual SM1241EN latest revision for troubleshooting procedures 12 REMOVING SECTION TRANSMISSION II 2 1 DRAINING TRANSMISSION Remove the drain plug from the pan Disconnect the transmission fill tube from the pan only if required Remove the fill tube completely if it interferes with transmission removal Examine the drained fluid for evidence of contamination refer to Paragraph 1 9 Install the drain plug and tighten it to 15 20 Ib 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 hydra
15. ant 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 AUTOM ATIC TRANSMISSION FLUID AND VISCOSITY GRADE Hydraulic fluids oils used in the transmission are important influences on transmission performance reliability and durability DEXRON III fluids are recommended for on highway applications Type C 4 fluids are recommended for severe duty and off highway applications Some DEXRON fluids are also qualified as Type C 4 fluids To ensure the fluid is qualified for use in Allison transmissions check for a DEXRON 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 result in transmission malfunction or reduced transmission life Y CAUTION Disregarding minimum fluid temperature limits can When choosing the optimum viscosity grade of fluid to use duty cycl
16. asuring 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 circuit after passing through a 0 032 inch 0 81 mm restriction Usually the restriction is already located in the PTO 3 6 INSTALLING SHIFT MODULATION CONTROL Install the modulation control after the transmission is put into the vehicle Referto Paragraph 5 9 21 PTO DRIVE GEAR 3RD RANGE CLUTCH SNAPRING BACKPLATE H00388 01 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 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 Ib ft 122 136 N m J beginning with S N 3210685574 where the oil pan boss length was changed from 0 575 to 0 675 inch Reference SIL 30 TR 94 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 22 3 8 INSTALLING NEUTRAL START AND REVERSE SIGNAL SWITCHES Connect any wiring requir
17. ches 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 1 3 DIPSTICK MARKINGS Earlier models use a dipstick marked FULL and ADD Figure 1 1 Later models use a dipstick marked COLD RUN and HOT RUN Figure 1 2 ustrates the marks in relation to the transmission NOTE The ADD and FULL dimensions on earlier dipsticks coincide J with the HOT RUN band dimensions on later dipsticks Q NOTE This illustration is not a template placement of markings will vary according EARLIER LATER to the installation angle of the dipstick tube MODELS MODELS vi Figure 1 1 Typical Dipstick Markings Ci TOP OF OIL PAN EARLIER E Y vy Vy MODELS FULL ADD LATER 0 50 in MODELS 12 7 m i HOT RUN 25 4 mm da re ill COLD RUN 1 50 in FILL TUBE ADAPTER HOLE 38 1 Meh in DRAIN PLUG 45 7 mm OIL PAN V03005 Figure 1 2 How Fluid Levels Are Established 1 4 FLUID CHECK PROCEDURE WARNING When checking the fluid level be sure the transmission is in N Neutral or P Park parking brake and or emergency brakes are set and properly engaged and the wheels are chocked Unexpected and possible sudden vehicle movement may occur if these precautions are not taken CAUTION Dirt and foreign matter must not be permitted to enter the f
18. ctor 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 or kinked cables lack of lubrication worn rod ends or clevis pins damaged threads or improper routing Parking brake control cracks bends damaged threads worn rod ends or 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 28 INSTALLING TRANSMISSION INTO SECTION VEHICLE V 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 converter retaining strap when the transmission is in position for installation 5 2 COUPLING TO ENGINE Align the flexplate and torque converter so that the drive bolts used X on all models except AT 543 or nuts AT 543 can be installed c Figure 2 1 A pilot too Figure 5 1 zan be used to maintain angnment on all AT mod
19. d thimble to convert it Besure the modulator control action is as required 34 e Install the O ring seal onto the modulator control Coat the O ring with oil soluble grease Install the modulator control into the transmission Install the control housing and secure it with the retainer and the 16 18 x 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 Ib ft 14 22 N m Some mechanical controls include a support bracket also secured by the retainer bolt Check the cable routing Bends must not be of less than 8 inches 20 cm radius 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 Adjust other types of mechanical controls as outlined in the vehicle manufacturer s instructions 5 10 CONNECTING POWER TAKEOFF CONTROLS f not previously installed mount the PTO on the transmission Paragraph 3 5 or 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 Ib ft 57 68 N m Connect and properly adjust the pa
20. e Put the transmission in the first range hold position Operate the vehicle at maximum speed in first range Apply the vehicle brakes while maintaining full 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 or P Park Increase engine speed to cool the torque converter NOTE Some engines have smoke controls and 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 With the transmission remaining in N Neutral or P Park run the engine at 1200 1500 rpm for two minutes to cool the fluid Atthe 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 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 tr
21. e preheat capabilities and or geographical location must be taken into consideration ists the minimum fluid temperatures at which the transmission may be safely operated Preheat with auxiliary heating equipment or by running the vehicle with the transmission in N Neutral or P Park for a minimum of 20 minutes before attempting range operation Table 1 1 Transmission Fluid Operating Temperature Requirements Viscosity Grade Ambient Temperature Below Which Preheat Is Required Fahrenheit Celsius SAE 0W 20 Arctic 31 35 DEXRONS III 22 30 SAE 10W 4 20 SAE 15W 40 5 15 SAE 30 32 0 SAE 40 50 10 1 7 FLUID AND FILTER CHANGE INTERVALS Fluid and filter change frequency is determined by severity of transmission service and by the filter equipment installed Table 1 2 s a general guide More frequent changes may be required when operations are subject to high levels of contamination or overheating Table 1 2 Fluid and Filter Change Intervals max or 12 months change interval AT External Auxiliar Transmission Fluid Change Internal Sump Filters y Paper Filter Paper Filter at After first 5000 25 000 miles each fluid change miles 8 000 km 40 000 km interval and at 25 000 miles On Highway or 12 months Brass Filter 40 000 km Light Duty Brass Filter 50 000 miles or 12 months 50 000 miles 80 000 km with thereafter 80 000 km no time limi
22. ed for sensors signals switches or other electrical components Install the Neutral Start Switch if so equipped into the opening directly above the selector shaft in the left side of the transmission housing 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 wrench J 33410 If the Neutral Start Switch is not mounted at this location plug the opening with a 34 16 plug with its head seated on a rubber coated washer Apply a light coat of thread sealant onto the threads of the reverse signal switch Install the switch into the right side of the transmission Tighten the switch to 4 5 Ib ft 5 7 N m Connect the wire leads NOTE An enhanced reverse pressure switch P N 29503665 became J available in November 1994 The improved switch is stamped with the 3 9 3 digit code 484 See SIL 7 TR 95 INSTALLING RETARDER CONTROLS Be sure that the low speed cutoff switch is reinstalled if removed in the opening provided at the left rear of the transmission Tighten the switch to 4 5 lb ft 5 7 N m
23. els with drive bolts drive connection should be statically or dynamically balanced to NOTE If a starter ring gear is welded to the flexplate the complete J reduce vibration e 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 center bore and 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 ten or twelve bolts that secure the transmission housing to the engine flywheel Bolts must be installed in the two uppermost bolt holes Tighten the bolts to the torque specified by the vehicle manufacturer capable of producing a tensile load of 8000 Ib 36 KN A nut that NOTE The drive cover nuts AT 543 must be self locking and J meets these requirements is Allison P N 23014107 29 FLYWHEEL HOUSING J DD J hi PILOT PLATE Make from M 10 x 38 mm CN 1 5 in Bolt PE TAPER JI Screwdriver slot to aid removal jd V03008 Figure 5 1 Pilot Tool for Installation AT 500 AT 1500 e Tighten the flexplate nuts AT 543 to 34 40 Ib ft 46 54 N m Tighten the drive cover bolts all models except AT 543 to 42 50 Ib ft 57 68 Nm 5 3 INSTALLING TRANSMIS
24. ent shafts and couplings 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 not satisfactory NOTE There are two coolers to check on an AT 500R transmission Cooler connecting lines clean and flush inspect for deterioration leaks faulty connectors kinks Minimum tube size required for cooler circuit is 0 5 inch 12 7 mm or No 8 hose size SAE 2 inch ID 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 27 NOTE For AT 500R transmissions the minimum size for primary J cooler hose is No 16 with a minimum ID of 0 875 inch 22 4 mm and for auxiliary cooler hose is No 8 with a minimum ID of 0 50 inch 12 7 mm If the hydraulic system has been contaminated with debris install an auxiliary filter between the cooler and transmission in cooler return line Paragraph 1 10 or filter recommendation and installation details 4 4 Vacuum or air modulator line and or hose inspect for deterioration bad connections loose or missing clamps or improper routing that causes kinks CHECKING CONTROLS Inspect transmission control components on vehicle and correct any faulty conditions Shift sele
25. explate e 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 AT 500 and AT 500N Series models with converter build date stamp before 9 84 1 600 1 740 inches 40 64 44 19 mm AT 500 AT 500R and AT 500N Series models with converter build date stamp of 9 84 or later 1 581 1 741 inches 40 16 44 22 mm AT 543 models 1 600 1 721 inches 40 64 43 71 mm AT 1500 Series models 2 715 2 875 inches 68 96 73 03 mm e A measurement outside these dimensions indicates the torque converter is not installed properly Refer to the applicable Allison Transmission Service Manual Refer to Paragraph 7 2 Measure over Measure retainer and or over lug spacer TRANSMISSION TRANSMISSION HOUSING HOUSING LUG SPACER OR SPACER AND CONVERTER RETAINER AT 540 AT 545 SERIES AT 543 AT 542 SERIES AT 1500 SERIES V03007 Figure 3 1 Converter Position Measurements 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 seal 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 Refer to Paragraph 7 2 Lubricate the
26. f excessive metal contamination has occurred replacement of the cooler and replacement of all bearings within the transmission is recommended Metal particles in the fluid 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 may need to 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 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 d Fluid Analysis Transmission protection and fluid change intervals can be optimized by monitoring oxidation according to the tests and limits shown in Table 1 4 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 Table 1 4
27. g at the earliest opportunity 2 6 REPAIR INSTRUCTIONS e Refer to the applicable Allison Transmission Service Manual to repair the transmission Refer to Paragraph 7 2 TORQUE CONVERTER RETAINING STRAP GOVERNOR COVER TORQUE CONVERTER OIL PAN MODULATOR SELECTOR RETAINER LEVER H00387 01 Figure 2 2 Location of Torque Converter Retaining Strap 16 PREPARING SHOTION TRANSMISSION FOR III 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 fl
28. he 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 14 1 5 1 6 1 7 1 8 1 9 1 10 1 11 1 12 Section Il 2 1 2 2 2 3 24 2 5 2 6 Section III 3 1 3 2 3 3 34 3 5 3 6 3 7 3 8 3 9 3 10 TABLE OF CONTENTS Description Page PREVENTIVE MAINTENANCE Periodic Inspection and Care 1 Importance of Proper Fluid Level 1 Dipstick Markings iaia 1 Fluid Check Procedure LL eee eee eee 3 Keeping Fluid Clean LL 4 Recommended Automatic Transmission Fluid and Viscosity Grade LL 4 Fluid and Filter Change Intervals 5 Fluid and Filter Change Procedure 6 Fluid Contamination LL 8 Auxiliary Filter ini ie ati 9 Breather creeranno pata epr 10 Trans
29. ing Transmission Mounting Components 30 5 4 Coupling to Driveline 0 00 0 000 2 31 5 5 Installing Vacuum or Air Modulator Control 31 5 6 Connecting Cooler Vacuum Lines Air Lines 32 5 7 Connecting Retarder Controls 32 5 8 Connecting Shift Selector Control 33 5 9 Installing Adjusting Mechanical Modulator Control 34 5 10 Connecting Power Takeoff Controls 35 5 11 Connecting Parking Brake Control 35 5 12 Connecting Speedometer Drive 0 0 35 5 13 Filling the Transmission LL 36 Section VI CHECKS AND ADJUSTMENT 6 1 Installation Checklist 37 6 2 Road Test and Vehicle Operation Checklist 40 Section VII CUSTOMER SERVICE 7 1 Owner Assistance LL 42 7 2 Service Literature coge kdo de UR es 44 PREFACE This handbook is a ready reference for the mechanic removing installing or maintaining AT 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 is a registered trademark of General Motors Corporation Loctite is a registered trademark of the Loctite Corporation Teflon is a registered
30. luid 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 the fluid level by the following procedures and record any abnormal fluid level milky appearance or any trace of coolant in the fluid on your maintenance records Refer to Paragraph 1 8 a Cold Check NOTE The only purpose of the Cold Check is to determine if the J transmission has enough fluid to be safely operated until a Hot Check can be made Park the vehicle on 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 or P Park and allow the engine to idle 500 800 rpm The sump temperature should be between 60 120 F 16 49 C 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
31. mission Stall Test and Neutral Cool Down Check 0 0 0 LL 10 REMOVING TRANSMISSION Draining Transmission 13 Disconnecting Controls 0 00 0 eee eee eee 13 Uncoupling Engine From Driveline 14 Removing Mounting Bolts LL 15 Removing Transmission 000s eee eee eee 15 Repair Instructions 15 PREPARING TRANSMISSION FOR INSTALLATION Checking Input Components 0 000 17 Checking Torque Converter Position 17 Installing Parking Brake and Output Flange 18 Installing Shift Selector Lever 00 0 0 19 Installing Power Takeoff PTO 0 0 0 0 02 005 20 Installing Shift Modulation Control 21 Installing Fill Tube and Drain Plug 22 Installing Neutral Start and Reverse Signal Switches 23 Installing Retarder Controls 0000005 23 Checking Breather 0 00 0 e eee eee eee 24 iii Paragraph Description Page Section IV PREPARING VEHICLE FOR TRANSMISSION INSTALLATION 4 1 Checking Flexplate Engine Features 25 4 2 Checking Chassis Driveline LL ern 27 4 3 Checking Cooler Tubes Hoses Fittings 27 44 Checking Controls ss i e 28 Section V INSTALLING TRANSMISSION INTO VEHICLE 5 1 Han dling i coe re need Wa eee 29 5 2 Coupling to Engine s sore isu R E eee eee eee 29 5 3 Install
32. ng harness to the electrical connector on the retarder valve body Figure 5 3 Insert the temperature sending unit into the retarder valve body Figure 5 3 Tighten the sending unit connector to 15 20 Ib ft 22 27 N m FROM PRIMARY COOLER TRANSMISSION FROM COOLER PORT CONNECTS TO TRANSMISSION MAIN PRESSURE TAP OPPOSITE SIDE OF TRANSMISSION RETARDER VALVE BODY TRANSMISSION TO COOLER PORT WIRING HARNESS CONNECTOR TO PRIMARY COOLER SENDING UNIT CONNECTS TO TRANSMISSION TO SECONDARY COOLER TO COOLER PORT L02889 01 Figure 5 3 AT 500R External Connections 32 5 8 CONNECTING SHIFT SELECTOR CONTROL e Place the operators shift selector control at the N Neutral position Place the selector lever hidden inside the transmission pan in the N Neutral position by one of the following two methods Figure 5 4 For vehicles with shift selectors with P Park position Rotate the selector shaft counterclockwise as far as it will go This puts the selector lever in the P Park position Carefully rotate the selector shaft clockwise two detents This puts the selector lever in the N Neutral position For vehicles with shift selectors without a P Park position Rotate the selector shaft counterclockwise as far as it will go This puts the selector lever in the R Reverse position Carefully rotate the selector shaft clockwise one detent This put
33. nt Allison 295 10923 Allison 295 10922 AC PM 13 16 PF 897 AC PM 16 1 PF141 FX 11583 HF6520 Fram HP 1 1 HP 1 or AC HD 222 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 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 ON The stall test provides a method for determining if the malfunction is in i the engine or in the transmission when a vehicle is not performing satisfactorily The neutral cool down check utilizes the two minute cooling period on 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 J 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 fo
34. ntacting 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 43 7 2 SERVICE LITERATURE Additional service literature is available This service literature provides fully 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 Transmission Service Parts Technician s Operator s Series Manual Catalog Guide Manual GN2055EN AT 542 SM1241EN PC2126EN GN2123EN OM1334EN AT 540 AT 543 GN2055EN AT 545 SM1241EN PC1235EN GN1948EN OM1334EN AT 1545 SM1241EN PC1235EN GN2055EN OM1334EN Automatic Transmission Fluid Principles of Operation 44 MT1321EN 199606 Printed in U S A 199804
35. o meet your parts and service needs with Expert service by trained personnel Emergency service 24 hours a day in many areas Complete parts support Sales teams to help determine your requirements 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 for the current listing of Allison Transmission authorized distributor 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
36. oil seal with petrolatum or transmission fluid 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 nstall the parking brake if so equipped Tighten the brake mounting bolts to 81 97 Ib ft 110 131 N m CAUTION Do not use a hammer or similar tool to install the output flange or yoke onto the transmission output shaft Internal damage can result 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 e The output flange is retained by a 4 20 x 1 inch bolt and a 16 inch 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 J 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 The torque value is the same for both bolts 3 4 INSTALLING SHIFT SELECTOR LEVER WARNING Second neutral models are equipped with an internal selector lever having two N Neutral positions This style lever may only be used with second neutral models If you mix one and second neutral parts the unit will not operate properly e g the vehicle may
37. oved 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 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 e 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 cable 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 e Later model actuators include a lever 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 indicates how the device is assembled e Conversion to the opposite mode of operation is only a matter of reassembling the internal parts Reverse the positions of the lever spring an
38. r the stall test WARNING When conducting a stall test the vehicle must be positively prevented from moving Apply the parking brake and service brake and block the vehicle securely 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 Run the engine at 1200 1500 rpm for two minutes to cool the transmission fluid between tests If the stall test is repeated do not let the engine overheat e Connecta 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 82 104 C 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 or P Park mechanisms These engines require the following stall test procedur
39. ransmission 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 llustrates the tooling required for these measurements Reference SIL 60 TR 81 latest revision B00389 01 Figure 4 1 Tooling Used to Determine the Adaptation Measurements of an AT 500 Series Transmission Table 4 1 Measurements Component or Required Inspections Limits Subassembly Bore Diameter 16 125 16 130 in Flywheel 409 58 409 70 mm Housing Bore Eccentricity 0 020 in 0 51 mm T LR Face Squareness 0 020 in 0 51 mm T LR Converter Pilot 1 703 1 705 in Crankshaft Hub Diameter 43 26 43 31 mm and or Adapter Face Squareness 0 0005 in 0 013 mm T I R Eccentricity 0 010 in 0 25 mm T LR Check for Radial None Permitted Cracks Flexplate Check for Elongated None Permitted Mounting Holes Check for Any Signs of None Permitted Distress and or Wear Axial Location Flatness AT 540 AT 542 1 600 1 740 in AT 545 models with 40 64 44 19 mm converter build date stamp before 9 84 AT 540 AT 542 1 581 1 741 in AT 545 models with 40 16 44 22 mm converter build date Mounted stamp of 9 84 Flexplate or Tafe AT 543 models AT 1500 models Flatness Formed Plates Flat Plates 1 600 1 721 in 40 64 43 71 mm 2 715
40. rking brake linkage Adjust the brake shoe to drum clearance as specified by the manufacturer 5 12 CONNECTING SPEEDOM ETER DRIVE Install the speedometer driven gear assembly into the transmission housing Tighten to 45 50 Ib 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 same as for driven gear assembly Do not operate transmission with the plastic shipping plug in this hole 35 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 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 36 CHECKS AND SECTION ADJUSTMENTS VI 6 1 INSTALLATION CHECKLIST PROPER TORQUE U Drive cover bolts AT 540 AT 542 AT 542N AT 545 AT 545N and AT 1500 Series 42 50 Ib ft 57 68 N m B Flexplate nuts AT 543 34 40 Ib ft 46 54 N m L Transmission to engine bolts O Transmission to frame mounting bolts 164 192 Ib ft 220 260 N m U Output flange retaining bolt 102 121 Ib ft 138 164 N m U Companion flange or universal joints bolts Q Manual selector lever nut 15 20 Ib ft 20 27 N m Q PTO mounting
41. s is required refer to the applicable AT Service Manual The shifts should occur at the following speeds 1 2 upshift occurs within 400 rpm of full load governed speed 2 3 upshift occurs within 300 rpm of full load governed speed 3 4 upshift occurs within 200 rpm of full load governed speed RETARDER C Check that the retarder responds correctly to 50 percent or 100 percent apply C Check that the retarder enable switch turns off the retarder B Check that retarder only applies at closed throttle C Check that low speed cutoff switch turns off the retarder in first range C 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 or P Park L Check for leaks O Warm up transmission and perform a fluid level hot check transmission in N Neutral or P Park and vehicle on a level surface OTHER CHECKS L Stall check B Shift quality O Comments 41 SECTION 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 t
42. s the selector lever in the N Neutral position 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 transmission detent 2N PARK O X D1 R r x N D D3 SECOND NEUTRAL RAMP VEHICLES WITH VEHICLES WITH SHIFT SHIFT SELECTOR SELECTOR WITHOUT WITH PARK POSITION PARK POSITION V00386 Figure 5 4 Identification of Internal Selector Levers 33 5 9 INSTALLING ADJUSTING MECHANICAL MODULATOR CONTROL NOTE There are 12V and 24V electric modulators available as of J June 1994 See SIL 27 TR 94 e 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 pin rem
43. se 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 Determining PTO Backlash PTO not installed backlash can be measured with special tool J 34814 Figure 3 3 Reference SIL 50 TR 83 latest revision PTO installed measure through the inspection port with a dial indicator while rotating PTO shaft back and forth Rattling gears indicate too much backlash Difficult engagement or whining gears indicate too tight a fit NOTE 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 20 TRANSMISSION MAIN CASE BASE PLATE GAUGE PIN MEASUREMENT PTO PAD 20 o Sel HOLD DOWN BOLT l3 J 34814 EN PTO DRIVE ST GEAR V02394 Measurement Correction 0 011 0 045 in 0 27 1 16 mm one 0 030 in Gasket one 0 76 mm Gasket 0 047 0 070 in 1 19 1 78 mm two 0 030 in Gaskets two 0 76 mm Gaskets Figure 3 3 Me
44. t or 24 months Paper or Brass Paper Filter at After first 5000 Filter 25 000 each fluid change miles 8 000 km On Highway miles 40 000 km interval and at normal fluid Heavy Duty or 12 months Brass Filter change intervals Retarder 50 000 miles thereafter 80 000 km with no time limit Paper or Brass Paper or Brass After first 500 hours Filter 1000 hours Filter at each fluid and at normal fluid Off Highway change intervals thereafter Whichever occurs first When an Allison high efficiency filter is used the change interval is until the Change Filter light indicates the filter is contaminated or until it has been in use for three years whichever occurs first No mileage restrictions apply A brass screen sump filter is available for all AT 500 and AT 1500 Series transmissions for both the shallow pan and the deep pan models To convert an AT deep pan 5 3 inches 135 mm with paper filter to the brass screen filter configuration a service conversion kit is required Refer to Service Information Letter SIL 5 TR 93 latest revision 1 8 FLUID AND FILTER CHANGE PROCEDURE a Drain The transmission should be at operating temperature to assist draining Remove the drain plug from the pan Disconnect the fill tube from the pan only if required Examine the drained fluid for evidence of contamination Remove the pan and filter Discard the pan gasket filter and filter
45. trademark of the DuPont Corporation B00616 01 Model AT 542 Transmission Left Front View B00617 01 Model AT 545 Transmission Right Front View Model AT 545R Transmission Right Front View vi 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 Hluid leaks correct immediately Shift linkage freely positioned by transmission detent Full and ease of movement of mechanical modulator linkage Vacuum leaks in the air line and modulator Damaged or loose fluid lines Worn or frayed electrical connections Worn out of phase driveline U joints and slip fittings Loose or missing speedometer cable 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 Pd power it is important that the proper fluid level be maintained at all times If the fluid level is too low the converter and clut
46. travel in R Reverse when D Drive is selected Be sure to install the appropriate internal selector ieved Refer ewe and to SIL 20 TR 93 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 a 78 16 nut standard inch series Use of the wrong nut will damage both the shaft and nut Torque for either nut is 15 20 Ib 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 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 Install the lever retaining nut finger tight against the lever Shift the selector 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 Ib ft 20 27 N m Figure 3 2 The lever must be seated fully against the shaft shoulder SELECTOR LEVER Ko E00394 Figure 3 2 Tightening Selector Lever Nut 3 5 INSTALLING POWER TAKEOFF PTO W CAUTION Cork or other soft gaskets must never be used to mount the PTO U
47. tube sealring Clean the pan Remove clean and reinstall the governor feed line screen in the control valve body For models with the shallow pan 3 8 inch 97 mm insert a new sealring into the filter tube Install the filter tube into the main housing Install a new brass screen sump filter onto the filter tube Bolt the filter onto the transmission Replace the pan gasket and reattach the pan reference Transmission Service Manual Tighten the pan screws to 10 15 Ib ft 14 20 N m NOTE To prevent leakage pan washer head screws must retain a J 5 Ib ft 7 N m minimum torque after gasket sets Install the drain plug into the pan and tighten it to 15 20 Ib ft 20 27 N m If removed install the fill tube and tighten the fill tube fitting in the pan boss to 65 75 1b ft 88 102 N m For models with the deep pan 5 3 inch 135 mm insert a new sealring into the filter tube Install the filter tube into the main housing When converting from paper filter to brass screen filter and for servicing the pan with the brass screen filter attach filter bracket see SIL 5 TR 93 Install the brass screen sump filter onto the filter tube Bolt the filter to the filter bracket Replace the pan gasket and reattach the pan reference Transmission Service Manual Tighten the pan screws to 10 15 Ib ft 14 20 N m NOTE To prevent leakage pan washer head screws must retain a J 5 Ib ft 7 N m minimum torque after gasket sets Install the dr
48. ulic lines and openings to prevent dirt from entering the hydraulic system 2 2 DISCONNECTING CONTROLS Disconnect the controls from the transmission and position them so they do not interfere with transmission removal 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 Disconnect the vacuum hose from the vacuum modulator if used Remove the vacuum modulator and plug the opening in the transmission Disconnect the power takeoff from its driven equipment Disconnect the PTO controls Remove the PTO completely if it will interfere with transmission removal Cover the PTO opening Disconnect any electrical leads to the retarder valve body or any sensors or other equipment on the transmission 2 3 UNCOUPLING ENGINE FROM DRIVELINE e Chock the wheels to prevent the vehicle from rolling x A e Disconnect the vehicle driveline from the transmission output flange or yoke Position the drive shaft to avoid interference with transmission removal Figure 2 1 shows two typical methods of coupling the engine and transmission Remove the six drive cover bolts all models except AT 543 or six flexplate nuts AT 543 SAE 2 FLYWHEEL HOUSING SAE 3 TO SAE 2 ADAPTER DRIVE COVER TRANSMISSION BOLT HOUSING FLEXPLATE FLYWHEEL RING GEAR ASSEMBLY ON CONVERTER DRIVE C
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