Allison Transmission 3000 Assembly instructions

MT3004EN
Mechanic’s Tips
3000 and 4000
Product Families

Allison Transmission
Allison WTEC III Controls
(Except 3000 Product Family 7-Speed)
Mechanic’s
Tips
2006 MARCH
MT3004EN
3000 Product Family
4000 Product Family
Printed in USA Copyright © 2007 Allison Transmission, Inc.
Allison Transmission, Inc.
P.O. Box 894 Indianapolis, Indiana 46206-0894
www.allisontransmission.com

2
NOTES

TABLE OF CONTENTS
SECTION I INTRODUCTION
1–1 ABOUT THIS MANUAL ............................... 7
SECTION II PREVENTIVE MAINTENANCE
2–1 PERIODIC INSPECTION AND CARE ...................... 20
2–2 IMPORTANCE OF PROPER TRANSMISSION FLUID LEVEL .......20
2–3 TRANSMISSION FLUID TEST ...........................21
2–4 KEEPING FLUID CLEAN ..............................27
2–5FLUIDRECOMMENDATIONS...........................27
2–6 TRANSMISSION FLUID AND FILTER CHANGE INTERVALS ...... 28
2–7 TRANSMISSION FLUID CONTAMINATION ..................32
2–8 TRANSMISSION FLUID AND FILTER CHANGE PROCEDURE ..... 35
2–9 FLUID LEAK DIAGNOSIS ............................. 37
2–10 BREATHER ...................................... 40
2–11 TROUBLESHOOTING ............................... 40
2–12 TRANSMISSION STALL TEST AND NEUTRAL COOL-DOWN
CHECK .........................................45
SECTION III REMOVING TRANSMISSION
3–1 DRAINING TRANSMISSION ............................51
3–2 DISCONNECTING CONTROLS .......................... 51
3–3 UNCOUPLING FROM DRIVELINE, ENGINE, AND VEHICLE ...... 52
3–4 REMOVING THE TRANSMISSION ........................53
3–5 REMOVING OUTPUT FLANGE OR YOKE ...................53
SECTION IV TRANSMISSION PREPARATION
4–1 INSPECTING INPUT COMPONENTS ...................... 55
4–2 INSTALLING OUTPUT FLANGE OR YOKE .................. 55
4–3 INSTALLING PTO ...................................56
4–4 INSTALLING FILL TUBE AND SEAL ...................... 57
4–5 INSPECTING PLUGS AND OPENINGS ..................... 58
3

SECTION V PREPARING VEHICLE FOR TRANSMISSION
INSTALLATION
5–1 ENGINE, TRANSMISSION ADAPTATION REQUIREMENTS ....... 59
5–2 CHECKING FLEXPLATE DRIVE ASSEMBLY .................62
5–3 CHASSIS AND DRIVELINE INSPECTION ................... 63
5–4 COOLER, FILTER, AND LINES .......................... 64
5–5 INSPECTING CONTROLS ............................. 65
SECTION VI INSTALLING TRANSMISSION INTO VEHICLE
6–1 HANDLING .......................................69
6–2 MOUNTING TO ENGINE .............................. 69
6–3 INSTALLING TRANSMISSION MOUNTING COMPONENTS ....... 70
6–4 COUPLING TO DRIVELINE ............................ 70
6–5 CONNECTING OUTPUT RETARDER ACCUMULATOR .......... 70
6–6 CONNECTING POWER TAKEOFF CONTROLS ................71
6–7 CONNECTING PARKING BRAKE CONTROL .................72
6–8 CONNECTING COOLER .............................. 72
6–9 CONNECTING ELECTRICAL COMPONENTS .................72
6–10 CONNECTING SPEEDOMETER DRIVE ....................74
6–11 FILLING HYDRAULIC SYSTEM ........................ 75
6–12 INSTALLATION INSPECTION LIST ...................... 75
SECTION VII INSPECTIONS AND ADJUSTMENTS
7–1 INSTALLATION INSPECTION LIST ....................... 76
7–2 ROAD TEST AND VEHICLE OPERATION INSPECTION LIST ...... 78
SECTION VIII CUSTOMER SERVICE
8–1 OWNER ASSISTANCE ................................80
8–2 SERVICE LITERATURE ............................... 80
4

TRADEMARK USAGE
The following trademarks are the property of the companies indicated:
•Allison DOC™ is a trademark of General Motors Corporation.
•DEXRON
®
is a registered trademark of the General Motors Corporation.
•TranSynd™ is a trademark of Castrol Ltd.
•LPS Electro Contact Cleaner
®
is a registered trademark of LPS
Laboratories.
5

WARNINGS, CAUTIONS, NOTES
IT IS YOUR RESPONSIBILITY to be completely familiar with the warnings
and cautions described in this handbook. It is, however, important to understand
that these warnings and cautions are not exhaustive. Allison Transmission could
not possibly know, evaluate, and advise the service trade of all conceivable ways
in which service might be done or of the possible hazardous consequences of each
way. The vehicle manufacturer is responsible for providing information related to
the operation of vehicle systems (including appropriate warnings, cautions, and
notes). 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 OR
THE VEHICLE MANUFACTURER 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 (or the
vehicle manufacturer) and described in this handbook are effective methods for
performing service operations. Some of these service operations require the use of
tools specially designed for the purpose. The special tools should be used when
and as recommended.
The following three types of headings are used in this manual to attract your
attention.
WARNING: A warning is used when an operating procedure, practice,
etc., if not correctly followed, could 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.
6

1–1. ABOUT THIS MANUAL
This handbook is a mechanic’s reference for maintaining, removing, or installing
the 3000 and 4000 Product Families on-highway transmission with a WTEC III
control system. WTEC III controls were optional on the 3000 and 4000 Product
Families on-highway transmission units built in 1997, but became standard on
units built starting in 1998.
All features of the transmission and the vehicle involved in installation procedures
are discussed. The information presented will help the mechanic maintain, remove,
or install the transmission in a manner that promotes satisfactory operation and
long service life. For additional detailed information, refer to the appropriate
transmission service manual and electronic controls troubleshooting manual.
Unless specifically indicated otherwise, this handbook refers to all 3000 and 4000
Product Families on-highway transmissions, except 7-speed models. The
differences between the various transmissions are explained as required.
INTRODUCTION Section I
7

V03350.08.00
OIL LEVEL SENSOR
P2 MODULE
P1 MODULE
CONVERTER MODULE • TURBINE • PUMP • LOCKUP CLUTCH/DAMPER • STATOR
CONVERTER HOUSING MODULE • CONVERTER HOUSING • PTO DRIVE GEAR ROTATING CLUTCH MODULE
• C1 CLUTCH • C2 CLUTCH • TURBINE SHAFT
CONTROL MODULE • ELECTRO-HYDRAULIC CONTROLS
MAIN SHAFT MODULE • MAIN SHAFT • P2 SUN • P3 SUN
MAIN HOUSING MODULE • MAIN HOUSING • C3 CLUTCH • C4 CLUTCH • C5 CLUTCH
FRONT SUPPORT/OIL PUMP MODULE • FRONT SUPPORT • OIL PUMP
REAR COVER MODULE • OUTPUT SHAFT • P3 • C5 PISTON
Figure 1–1. 3000 Product Family Transmission
with PTO—Cross Section
8

ROTATING CLUTCH MODULE C1 CLUTCH C2 CLUTCH TURBINE SHAFT
CONTROL MODULE ELECTRO-HYDRAULIC CONTROLS
P1 MODULE P2 MODULE
MAIN HOUSING MODULE MAIN HOUSING C3 CLUTCH C4 CLUTCH C5 CLUTCH MAIN SHAFT MODULE
MAIN SHAFT P2 SUN P3 SUN
REAR COVER MODULE OUTPUT SHAFT P3 MODULE C5 PISTON
V07286.02.00
CONVERTER MODULE
TURBINE
PUMP
STATOR
LOCKUP
CLUTCH/DAMPER
CONVERTER HOUSING MODULE
CONVERTER HOUSING
FRONT SUPPORT/OIL PUMP MODULE
FRONT SUPPORT
OIL PUMP
Figure 1–2. 3000 Product Family Transmission—Cross Section
9

V07287.06.00
MAIN HOUSING MODULE MAIN HOUSING C3 CLUTCH C4 CLUTCH C5 CLUTCH
ROTATING CLUTCH MODULE C1 CLUTCH C2 CLUTCH TURBINE SHAFT
CONTROL MODULE ELECTRO-HYDRAULIC CONTROLS
P3 MODULE
P2 MODULE
P1 MODULE
MAIN SHAFT MODULE MAIN SHAFT P2 SUN P3 SUN
RETARDER MODULE STATOR ASSEMBLY ROTOR HOUSING ASSEMBLY
CONVERTER HOUSING MODULE
CONVERTER HOUSING
FRONT SUPPORT/OIL PUMP MODULE
FRONT SUPPORT
OIL PUMP
CONVERTER MODULE
TURBINE
PUMP
STATOR
LOCKUP
CLUTCH/DAMPER
Figure 1–3. 4000 Product Family Transmission
with Retarder—Cross Section
10

V07288.03.00
MAIN HOUSING MODULE MAIN HOUSING C3 CLUTCH C4 CLUTCH C5 CLUTCH
ROTATING CLUTCH MODULE C1 CLUTCH C2 CLUTCH TURBINE SHAFT
CONTROL MODULE ELECTRO-HYDRAULIC CONTROLS
P2 MODULE P1 MODULE
MAIN SHAFT MODULE MAIN SHAFT P2 SUN P3 SUN
REAR COVER MODULE OUTPUT SHAFT P3 MODULE C5 PISTON
CONVERTER HOUSING MODULE
CONVERTER HOUSING
PTO DRIVE GEAR
FRONT SUPPORT/OIL PUMP MODULE
FRONT SUPPORT
OIL PUMP
CONVERTER MODULE
TURBINE
PUMP
STATOR
LOCKUP
CLUTCH/DAMPER
Figure 1–4. 4000 Product Family Transmission
with PTO—Cross Section
11

V05641.03.00
ENIBRUT• PMUP• ROTATS• PUKCOL• /HCTULC REPMAD
PMUPLIO• TROPPUSTNORF•
ELUDOMPMUPLIO/TROPPUSTNORF GNISUOHNIAM• HCTULC3C• HCTULC4C• HCTULC5C•
ELUDOMGNISUOHNIAM
ELUDOMRETREVNOC
TFAHSENIBRUT• HCTULC1C• HCTULC2C•
ELUDOMHCTULCGNITATOR
•GNISUOHRETREVNOC
RETREVNOC ELUDOMGNISUOH
•TFAHSNIAM NUS3P• NUS2P•
TFAHSNIAM ELUDOM
ELUDOM3P ELUDOM2P ELUDOM1P
GNISUOHRETPADA6C••HCTULC6C ELUDOM4P•
GNISUOHRETPADA6C ELUDOM
•REVOCRAER •TFAHSTUPTUO
REVOCRAER ELUDOM
Figure 1–5. 4000 Product Family Transmission
7-Speed—Cross Section
12

PTO
PROVISION
OUTPUT
SPEED
SENSOR
NAMEPLATE
RIGHT-REAR VIEW
LEFT-FRONT VIEW
INPUT
SPEED
SENSOR
ASSEMBLY PADS
MAIN-PRESSURE TAP
NOTE: Inch Series Threads
BREATHER
FEEDTHROUGH HARNESS
CONNECTOR
COOLER PORTS
NOTE: Inch Series Threads
V07289.02.00
ASSEMBLY PADS
(BOTH SIDES)
BREATHER
MAIN-PRESSURE TAP
NOTE: Inch Series Threads
FEEDTHROUGH HARNESS
CONNECTOR
TORQUE CONVERTER
WITH LOCKUP CLUTCH
AND TORSIONAL DAMPER
PTO PROVISION
(AVAILABLE BOTH SIDES)
Figure 1–6. 3000 Product Family Transmission with PTO
13

ASSEMBLY PADS
(BOTH SIDES)
TO RETARDER
ACCUMULATOR
OIL FILL TUBE AND
DIPSTICK
(AVAILABLE ON
BOTH SIDES
)
OUTPUT
RETARDER
TORQUE CONVERTER
WITH LOCKUP CLUTCH
AND TORSIONAL DAMPER
BREATHER
MAIN-PRESSURE TAP
NOTE: Inch series threads
FEEDTHROUGH
HARNESS
CONNECTOR
INPUT SPEED
SENSOR
NAMEPLATE
ASSEMBLY PADS
MAIN-PRESSURE TAP
NOTE: Inch Series Threads
BREATHER
COOLER PORTS
NOTE: Inch Series Threads
RIGHT-REAR VIEW
LEFT-FRONT VIEW
V07290.01.00
Figure 1–7. 3000 Product Family Transmission with Retarder
14

ASSEMBLY PADS
(BOTH SIDES)
TO RETARDER
ACCUMULATOR
OIL FILL TUBE
AND DIPSTICK
(AVAILABLE ON
BOTH SIDES
)
OUTPUT
RETARDER
TORQUE CONVERTER
WITH LOCKUP CLUTCH
AND TORSIONAL DAMPER
BREATHER
MAIN-PRESSURE TAP
NOTE: Inch series threads
FEEDTHROUGH
HARNESS
CONNECTOR
RETARDER
VALVE BODY
CONNECTOR
OUTPUT
SPEED
SENSOR
ASSEMBLY PADS
MAIN-PRESSURE TAP
NOTE: Inch Series Threads
BREATHER
COOLER PORTS
NOTE: Inch Series Threads
LEFT-REAR VIEW
LEFT-FRONT VIEW
V07300.01.00
TACHOGRAPH PROVISION
NOTE: Metric Series Threads
SPEEDOMETER PROVISION
NOTE: Inch Series Threads
Figure 1–8. 3000 Product Family Transmission with Retarder and
Provisions for Tachograph and Speedometer
15

FEEDTHROUGH
HARNESS
CONNECTOR
RETARDER
VALVE BODY
CONNECTOR
OUTPUT
SPEED
SENSOR
ASSEMBLY PADS
MAIN-PRESSURE TAP
NOTE: Inch Series Threads
BREATHER
COOLER PORTS
NOTE: Inch Series Threads
TACHOGRAPH PROVISION
NOTE: Inch Series Threads
ASSEMBLY PADS
(BOTH SIDES)
TO RETARDER
ACCUMULATOR
OIL FILL TUBE
AND DIPSTICK
(AVAILABLE ON
BOTH SIDES
)
OUTPUT
RETARDER
TORQUE CONVERTER
WITH LOCKUP CLUTCH
AND TORSIONAL DAMPER
BREATHER
MAIN-PRESSURE TAP
NOTE: Inch series threads
LEFT-REAR VIEW
LEFT-FRONT VIEW
V07401.02.00
Figure 1–9. 3000 Product Family Transmission with Retarder and
Provisions for Tachograph and Sump Cooler
16

TURBINE SPEED
SENSOR
MOUNTING
PAD
SHIPPING
BRACKET (3)
ENGINE SPEED
SENSOR
NAMEPLATE
FILL TUBE
OUTPUT SPEED
SENSOR
FEEDTHROUGH
HARNESS
CONNECTOR
PTO
(TOP RIGHT POSITION)
V07291.00.01
COOLER PORTS
PTO
(BOTTOM LEFT
POSITION)
MAIN-PRESSURE TAP
MOUNTING PAD
(BOTH SIDES)
COOLER PORTS
FEEDTHROUGH
HARNESS
CONNECTOR
RIGHT-REAR VIEW
LEFT-REAR VIEW
Figure 1–10. 4000 Product Family Transmission with PTO
17

V07292.03.00
RIGHT-FRONT VIEW
LEFT-REAR VIEW
PTO (TOP RIGHT POSITION)
RETARDER
FEEDTHROUGH
HARNESS
CONNECTOR
COOLER PORTS
PTO (TOP RIGHT POSITION)
MOUNTING PADS
(BOTH SIDES)
MOUNTING PADS
(BOTH SIDES)
FILL TUBE
TURBINE
SPEED
SENSOR ENGINE SPEED SENSOR
PTO (BOTTOM LEFT
POSITION)
MAIN-PRESSURE TAP
NAMEPLATE
FEEDTHROUGH
HARNESS
CONNECTOR
RETARDER
SUMP
COOLER
PROVISION
Figure 1–11. 4000 Product Family Transmission with Retarder and PTO
18

V07399.00.02
LEFT-REAR
LEFT-REAR
FEEDTHROUGH
HARNESS
CONNECTOR
C6 ADAPTER
HOUSING
REAR COVER
C6 ADAPTER
HOUSING
SUMP
COOLER
PROVISION
RETARDER
COOLER
PORTS
PTO (TOP RIGHT POSITION)
PTO (TOP RIGHT POSITION)
MOUNTING PADS
(BOTH SIDES)
MOUNTING PADS
(BOTH SIDES)
PTO (BOTTOM LEFT
POSITION)
PTO (BOTTOM LEFT
POSITION)
MAIN-PRESSURE TAP
MAIN-PRESSURE TAP
Figure 1–12. 4000 Product Family 7-Speed Transmission
with PTO (Top) and 7-Speed with PTO and Retarder (Bottom)
19