4K Service Manual 4th Gen SM4014EN 200510

Service Manual

2005 OCTOBER SM4014EN

Allison Transmission ALLISON 4TH GENERATION CONTROLS VOCATIONAL MODELS 4000 EVS 4000 HS 4000 MH 4000 RDS 4000 SP 4000 TRV

4500 EVS 4500 HS 4500 RDS 4500 SP

4700 EVS 4700 RDS 4700 SP

4800 EVS 4800 SP

Allison Transmission, General Motors Corporation P.O. Box 894 Indianapolis, Indiana 46206-0894 www.allisontransmission.com Printed in USA

Copyright © 2005 General Motors Corporation

B 500 T 425 T 450 T 525

INTRODUCTION ELECTRONIC CONTROL UNIT AND DIAGNOSTIC DATA READER/TOOL DISPLAYS AND BUTTON NAMES ↑ (Up), ↓ (Down), Shift Selector, Allison DOC™ button, and display names are printed in bold capital letters—↑ MODE, MONITOR, SELECT, etc. Transmission range shifts are indicated by the letter or number on the shift selector, in bold text, followed by the name of the range in parentheses—D (Drive), N (Neutral), etc. References to diagnostic messages displayed are printed within double quotation marks (“OL,” “OK,” etc.).

TRADEMARK USAGE The following trademarks are the property of the companies indicated: • Allison DOC™ (Allison Diagnostic Optimized Connection Tool) is a trademark • • • • • •

of General Motors Corp. DEXRON® is a registered trademark of General Motors Corp. Biobor® JF is the registered trademark for a biological inhibitor manufactured by U.S. Borax and Chemical Corporation. Loctite® is a registered trademark of the Loctite Corporation. Teflon® is a registered trademark of the DuPont Corporation. TranSyndTM is a trademark of Castrol, Ltd. Vespel® is a registered trademark of DuPont Corporation.

NOTE: This publication is revised periodically to include improvements, new models, special tools, and procedures. A revision is indicated by the date on the title page. Check with your Allison Transmission service outlet for the currently applicable publication. Additional copies of this publication may be purchased from authorized Allison Transmission service outlets. Look in your telephone directory under the heading of Transmissions—Truck, Tractor, etc.

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Copyright © 2005 General Motors Corp.

IMPORTANT SAFETY NOTICE IT IS YOUR RESPONSIBILITY to be completely familiar with the Warnings and Cautions described in this Service Manual. These Warnings and Cautions advise against the use of specific service methods that can result in personal injury, damage to the equipment, or cause the equipment to become unsafe. 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 are important to the safe, reliable operation of the equipment. The service procedures recommended by Allison Transmission and described in this Service Manual are effective methods for performing service operations. Some of these service operations require the use of tools specifically designed for the purpose. The special tools should be used when and as recommended.

WARNINGS, CAUTIONS, AND NOTES Three types of headings are used in this manual to attract your attention: WARNING! is used when an operating procedure, practice, etc., which, if not correctly followed, could result in personal injury or loss of life.

CAUTION: is used when an operating procedure, practice, etc., which, if not strictly observed, could result in damage to or destruction of equipment.

NOTE: is used when an operating procedure, practice, etc., is essential to highlight.


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LIST OF WARNINGS This manual contains the following Warnings — IT IS YOUR RESPONSIBILITY TO BE FAMILIAR WITH ALL OF THEM. If you leave the vehicle and the engine is running, the vehicle can move suddenly and you or others could be injured. If you must leave the engine running, do not leave the vehicle until you: • Put the transmission in N (Neutral)…and • Apply the parking brake and emergency brakes and make sure they are properly engaged…and • Chock the wheels and take any other steps necessary to keep the vehicle from moving. Avoid contact with the hot fluid or the hot sump when draining transmission fluid. Direct contact with the hot fluid or the hot sump may result in bodily injury. DO NOT conduct a converter stall test until the following actions are taken. The parking brake and/or emergency brakes must be set and properly engaged and the wheels must be chocked. Warn personnel to keep clear of the vehicle and its travel path. Failure to do so can cause serious injury. Use appropriate safety equipment such as safety glasses, safety shoes, and gloves. Do not burn discarded Teflon® seals; toxic gases are produced by burning Teflon®. Never dry bearings by spinning them with compressed air. A spinning bearing can disintegrate, allowing balls or rollers to become lethal flying projectiles. Also, spinning a bearing without lubrication can damage the bearing. DO NOT disconnect the hydraulic fluid line between the accumulator and the retarder until air and hydraulic pressure have been bled from the retarder. PREVENT PERSONAL INJURY: Use proper tools and lifting equipment when installing or removing a transmission from the repair stand. Transmission dry weights are as follows: • 4000 and 4500 Models Base transmission —377 kg (831 lbs) With PTO provision —405 kg (893 lbs) With retarder —411 kg (906 lbs) With retarder and PTO provision —439 kg (968 lbs) • 4700 and 4800 Models Base transmission With PTO provision With retarder With retarder and PTO provision With retarder, PTO, and integral retarder sump cooler

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—493 kg (1087 lbs) —521 kg (1149 lbs) —529 kg (1162 lbs) —555 kg (1224 lbs) —496 kg (1032 lbs)


LIST OF WARNINGS This manual contains the following Warnings — IT IS YOUR RESPONSIBILITY TO BE FAMILIAR WITH ALL OF THEM. Get help when lifting the control module. Assistance from a hoist or another person may be required. The control module weighs approximately 25 kg (55 lb). Get help when lifting the retarder module. Assistance from a hoist or another person may be required. The retarder module weighs approximately 34 kg (75 lb). Get help when lifting the C6 adapter housing module. Assistance from a hoist or another person may be required. The C6 adapter housing module weighs approximately 68 kg (150 lb). Carefully release spring force. Piston springs are highly compressed. Personal injury can occur if the spring force is not controlled. Piston springs are highly compressed. Be extremely careful during removal and installation. Personal injury can occur if the spring force is not controlled. Place the P3 planetary assembly on its side to avoid possible injury while disassembling the planetary.


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INTRODUCTION NOTES

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TABLE OF CONTENTS Paragraph

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Section 1. GENERAL INFORMATION 1–1. SCOPE OF MANUAL a. Content And Organization. . . . . . . . . . . . 1–1 b. Illustrations. . . . . . . . . . . . . . . . . . . . . . . . 1–1 c. Maintenance Information . . . . . . . . . . . . 1–1 1–2. SUPPLEMENTARY INFORMATION . . . . 1–5 1–3. ORDERING PARTS a. Transmission Nameplate . . . . . . . . . . . . . 1–5 b. Parts Catalog . . . . . . . . . . . . . . . . . . . . . . 1–5 1–4. GENERAL DESCRIPTION a. Major Modules. . . . . . . . . . . . . . . . . . . . . 1–5 b. Unique Features. . . . . . . . . . . . . . . . . . . . 1–5 1–5. MAJOR COMPONENTS a. Input Module . . . . . . . . . . . . . . . . . . . . . . 1–6 b. Torque Converter . . . . . . . . . . . . . . . . . . . 1–6 c. Power Takeoff . . . . . . . . . . . . . . . . . . . . . 1–6 d. Main Housing And Gear Module . . . . . . 1–6 e. Range Clutches . . . . . . . . . . . . . . . . . . . . 1–6 f. Control System . . . . . . . . . . . . . . . . . . . . 1–6 g. Transmission Fluid Filters . . . . . . . . . . . . 1–6 h. Transmission Fluid Coolers . . . . . . . . . . . 1–6 i. C6 Adapter Housing Module. . . . . . . . . . 1–6 j. Rear Cover . . . . . . . . . . . . . . . . . . . . . . . . 1–6 k. Output Retarder And Output Flange . . . . 1–6 1–6. 4000 PRODUCT FAMILY MODEL DESIGNATION CODE . . . . . . . . . . . . . . . . 1–6 1–7. EXPLODED (DISASSEMBLED) VIEWS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–7 1–8. DIAGNOSIS a. Before Starting . . . . . . . . . . . . . . . . . . . . . 1–7 b. CHECK TRANS Light . . . . . . . . . . . . . . 1–7 c. Entering Diagnostic Mode . . . . . . . . . . . 1–8 d. Diagnostic Codes . . . . . . . . . . . . . . . . . . . 1–8 e. Displaying Diagnostic Codes . . . . . . . . . 1–8 f. Diagnostic Code Displays . . . . . . . . . . . . 1–8 g. Exiting Diagnostic Mode . . . . . . . . . . . . 1–8 1–9. PRESERVATION AND STORAGE a. Storage (New Transmissions, Before Installation) . . . . . . . . . . . . . . . . . 1–8 b. Preservation Methods . . . . . . . . . . . . . . . 1–8 c. One Year Storage (Without Fluid). . . . . . 1–8 d. One Year Storage (With Fluid) . . . . . . . . 1–9

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1–10. RESTORING TRANSMISSION TO SERVICE a. Transmission Exterior . . . . . . . . . . . . . . . 1–9 b. Sealed Breather And Openings . . . . . . . . 1–9 c. New Transmissions . . . . . . . . . . . . . . . . . 1–9 d. Stored Without Fluid . . . . . . . . . . . . . . . . 1–9 e. Stored With Fluid. . . . . . . . . . . . . . . . . . . 1–9 1–11. ELECTROMAGNETIC/RADIO FREQUENCY INTERFERENCE . . . . . . . 1–10 1–12. OPERATING INSTRUCTIONS . . . . . . . . 1–10 1–13. SPECIFICATIONS AND DATA . . . . . . . . 1–10

Section 2. PREVENTIVE MAINTENANCE 2–1. SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1 2–2. PERIODIC INSPECTION AND CARE a. Exterior Cleaning And Inspection. . . . . . 2–1 2–3. IMPORTANCE OF PROPER FLUID LEVEL a. Transmission Fluid . . . . . . . . . . . . . . . . . 2–1 b. Oil Level Sensor . . . . . . . . . . . . . . . . . . . 2–1 c. Electronic Controls And Protection Circuits . . . . . . . . . . . . . . . . . . 2–1 2–4. ELECTRONIC FLUID LEVEL CHECK (WHEN AN OPTIONAL OLS IS PRESENT—FULL-FUNCTION PUSHBUTTON OR LEVER SHIFT SELECTORS) a. Fluid Level Check Procedure . . . . . . . . . 2–2 2–5. MANUAL FLUID LEVEL CHECK PROCEDURE a. Preparation . . . . . . . . . . . . . . . . . . . . . . . 2–3 b. Consistency Of Readings . . . . . . . . . . . . 2–3 2–6. COLD CHECK a. Purpose. . . . . . . . . . . . . . . . . . . . . . . . . . . 2–3 b. Cold Check Procedure . . . . . . . . . . . . . . . 2–3 2–7. HOT CHECK a. Purpose. . . . . . . . . . . . . . . . . . . . . . . . . . . 2–4 b. Cold Check Procedure . . . . . . . . . . . . . . . 2–4 2–8. KEEPING FLUID CLEAN. . . . . . . . . . . . . . 2–4 2–9. FLUID RECOMMENDATIONS a. Fluid Type . . . . . . . . . . . . . . . . . . . . . . . . 2–5


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4000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4 th GENERATION Paragraph

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2–10. FLUID AND FILTER CHANGE INTERVALS a. Fluid And Filter Changes . . . . . . . . . . . . 2–5 b. Fluid Analysis . . . . . . . . . . . . . . . . . . . . . 2–7

2–17. OUTPUT FLANGE/YOKE AND OIL SEAL MAINTENANCE

2–11. FLUID CONTAMINATION a. Water . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–7 b. Engine Coolant . . . . . . . . . . . . . . . . . . . . 2–7 c. Metal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–7

2–18. ON-VEHICLE MAINTENANCE . . . . . . . 2–18

2–12. FLUID AND FILTER CHANGE PROCEDURE a. Drain Fluid . . . . . . . . . . . . . . . . . . . . . . . 2–7 b. Replace Filters. . . . . . . . . . . . . . . . . . . . . 2–8 c. Refill Transmission . . . . . . . . . . . . . . . . . 2–8

3–1. SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1

2–13. BREATHER a. Location And Purpose. . . . . . . . . . . . . . . 2–8 b. Maintenance . . . . . . . . . . . . . . . . . . . . . . 2–9 2–14. TRANSMISSION STALL TEST AND NEUTRAL COOL-DOWN CHECK a. Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . 2–9 b. Stall Testing Preparation. . . . . . . . . . . . . 2–9 c. Performing a Transmission Stall Test . 2–10 d. Driving Transmission Stall Test . . . . . . 2–10 e. Driving Transmission Stall Test Preparation . . . . . . . . . . . . . . . . . . . . . . 2–10 f. Performing a Driving Transmission Stall Test . . . . . . . . . . . . . . . . . . . . . . . . . 2–11 g. Neutral Cool-Down Procedure. . . . . . . 2–11 h. Transmission Stall Test Results . . . . . . 2–11 2–15. READING CLUTCH PRESSURES a. Purpose . . . . . . . . . . . . . . . . . . . . . . . . . b. Transmission And Vehicle Preparation . c. Recording Data . . . . . . . . . . . . . . . . . . . d. Comparing Recorded Data To Specifications. . . . . . . . . . . . . . . . . .

2–12 2–12 2–12 2–13

2–16. FLUID LEAK DIAGNOSIS a. Finding Leak . . . . . . . . . . . . . . . . . . . . . 2–16 b. Powder Method . . . . . . . . . . . . . . . . . . . 2–16 c. Black Light and Dye Method . . . . . . . . 2–16 d. Possible Points Of Fluid Leaks And Their Causes . . . . . . . . . . . . . . . . . . . . . 2–16 e. Repairing Leak . . . . . . . . . . . . . . . . . . . 2–17 viii

a. Disassembly . . . . . . . . . . . . . . . . . . . . . 2–17 b. Assembly. . . . . . . . . . . . . . . . . . . . . . . . 2–18

Section 3. GENERAL OVERHAUL INFORMATION

3–2. TOOLS AND EQUIPMENT a. Improvised Equipment . . . . . . . . . . . . . . 3–1 b. Special Tools . . . . . . . . . . . . . . . . . . . . . . 3–1 c. Mechanic’s Tools And Shop Equipment . . . . . . . . . . . . . . . . . . . 3–1 3–3. REPLACEMENT PARTS a. Ordering Information . . . . . . . . . . . . . . . 3–6 b. Parts Normally Replaced at Overhaul . . . . . . . . . . . . . . . . . . . . . . . 3–6 3–4. CAREFUL HANDLING . . . . . . . . . . . . . . . 3–6 3–5. CLEANING AND INSPECTION a. Dirt Causes Malfunction . . . . . . . . . . . . . 3–6 b. Cleaning Transmission, Parts . . . . . . . . . 3–6 c. Cleaning Bearings. . . . . . . . . . . . . . . . . . 3–6 d. Inspecting Bearings. . . . . . . . . . . . . . . . . 3–7 e. Keeping Bearings Clean . . . . . . . . . . . . . 3–7 f. Inspecting Cast Parts and Machined Surfaces . . . . . . . . . . . . . . . . . 3–7 g. Inspecting Bushings and Thrust Washers . . . . . . . . . . . . . . . . . . . . 3–7 h. Inspecting Sealrings and Gaskets . . . . . . 3–8 i. Inspecting Gears . . . . . . . . . . . . . . . . . . . 3–8 j. Inspecting Splined Parts . . . . . . . . . . . . . 3–8 k. Inspecting Threaded Parts. . . . . . . . . . . . 3–8 l. Inspecting Retaining Rings . . . . . . . . . . . 3–9 m. Inspecting Springs. . . . . . . . . . . . . . . . . . 3–9 n. Inspecting Clutch Plates . . . . . . . . . . . . . 3–9 o. Inspecting Swaged and Interference-Fit Parts . . . . . . . . . . . . . . . 3–9 p. Inspecting Sealing Surfaces . . . . . . . . . . 3–9



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3–6. ASSEMBLY PROCEDURES a. Parts Lubrication . . . . . . . . . . . . . . . . . . . 3–9 b. Grease Used For Assembly . . . . . . . . . . . 3–9 c. Sealing Compounds And Nonsoluble Greases . . . . . . . . . . . . . . . . . 3–9 d. Clutches And Pistons. . . . . . . . . . . . . . . . 3–9 e. Threaded Plugs And Hydraulic Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . 3–10 f. Coated Threaded Fasteners . . . . . . . . . . 3–10 g. Lip-Type Oil Seals. . . . . . . . . . . . . . . . . 3–10 h. Butt-Joint Sealrings . . . . . . . . . . . . . . . . 3–10 i. Bearings . . . . . . . . . . . . . . . . . . . . . . . . . 3–10 j. Bushings. . . . . . . . . . . . . . . . . . . . . . . . . 3–11 k. Electrical Components . . . . . . . . . . . . . 3–11 3–7. REMOVING TRANSMISSION FROM VEHICLE a. Drain Fluid. . . . . . . . . . . . . . . . . . . . . . . 3–11 b. Disconnecting Controls . . . . . . . . . . . . . 3–11 c. Uncoupling Transmission From Vehicle And Engine Driveline. . . . . . . . 3–11 d. Removing The Transmission. . . . . . . . . 3–12 3–8. WEAR LIMITS . . . . . . . . . . . . . . . . . . . . . . 3–12 3–9. SPRING SPECIFICATIONS . . . . . . . . . . . 3–12 3–10. TORQUE SPECIFICATIONS . . . . . . . . . . 3–12

Section 4. TRANSMISSION DISASSEMBLY 4–1. SCOPE a. Section . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1 b. Procedures . . . . . . . . . . . . . . . . . . . . . . . . 4–1 c. Illustrations. . . . . . . . . . . . . . . . . . . . . . . . 4–1 d. General Information. . . . . . . . . . . . . . . . . 4–1 e. Foldouts . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1 4–2. DISASSEMBLY OF TRANSMISSION a. Mounting Transmission On Repair Stand. . . . . . . . . . . . . . . . . . . . 4–1 b. Removal Of Power Takeoff. . . . . . . . . . . 4–1 c. Removal Of External Parts . . . . . . . . . . . 4–1 d. Removal Of Integral Oil Cooler . . . . . . . 4–3 e. Removing Integral Retarder Sump Oil Cooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–3 f. Removal Of Control Valve Module . . . . 4–4 g. Removal Of Torque Converter Module. . 4–4 h. Removal Of Converter Housing Module . . . . . . . . . . . . . . . . . . . 4–6 i. Removal Of Retarder Module (Except 4700 And 4800 Models). . . . . . . 4–6

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j. Removal Of Retarder And Output Shaft Module (4700 And 4800 Models) . . . . . . 4–7 k. Removal Of Rear Cover Module (Except 4700 And 4800 Models) . . . . . . . . . . . . . 4–7 l. Removal Of Rear Cover And Output Shaft Module (4700 And 4800 Models) . 4–8 m. Removal Of C6 Adapter Housing Module (4700 And 4800 Models) . . . . . . 4–8 n. Removal Of P3 Planetary Module (4700 And 4800 Models). . . . . . . . . . . . . 4–9 o. Removal Of Main Shaft Module . . . . . . . 4–9 p. Removal Of P2 Module, C5 Clutch Plates, And P1 Module. . . . . . 4–9 q. Removal Of Front Support/ Charging Pump Module And Rotating Clutch Module . . . . . . . . . . . . 4–10 r. Removal Of C3/C4 Clutch Assembly From Main Housing Module. . . . . . . . . 4–10

Section 5. MODULE REBUILD 5–1. SCOPE a. Section . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1 b. Procedures . . . . . . . . . . . . . . . . . . . . . . . . 5–1 5–2. GENERAL INFORMATION FOR MODULE REBUILD . . . . . . . . . . . . . . . . . . 5–1 5–3. TORQUE CONVERTER MODULE a. Disassembly . . . . . . . . . . . . . . . . . . . . . . . 5–1 b. Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 5–2 5–4. TORQUE CONVERTER HOUSING MODULE (Models Without PTO Provision) a. Disassembly . . . . . . . . . . . . . . . . . . . . . . . 5–4 b. Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 5–4 5–5. TORQUE CONVERTER HOUSING MODULE (Models With PTO Provision) a. Disassembly . . . . . . . . . . . . . . . . . . . . . . . 5–4 b. Disassembly Of Bearing Retainer. . . . . . 5–4 c. Disassembly Of PTO Gear Assembly. . . 5–4 d. Assembly Of PTO Gear Assembly . . . . . 5–4 e. Assembly Of Bearing Retainer Assembly. . . . . . . . . . . . . . . . . . 5–5 f. Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 5–5


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5–6. FRONT SUPPORT AND OIL PUMP MODULE a. Disassembly . . . . . . . . . . . . . . . . . . . . . . 5–5 b. Assembly Of Front Support . . . . . . . . . . 5–7 c. Assembly Of Pump Housing . . . . . . . . . 5–7 5–7. ROTATING CLUTCH MODULE a. Disassembly . . . . . . . . . . . . . . . . . . . . . . 5–8 b. Assembly . . . . . . . . . . . . . . . . . . . . . . . . 5–11 5–8. C3/C4 AND MAIN HOUSING MODULE a. Disassembly . . . . . . . . . . . . . . . . . . . . . 5–12 b. Assembly . . . . . . . . . . . . . . . . . . . . . . . . 5–13

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e. Disassembly Of Retarder Stator Assembly . . . . . . . . . . . . . . . . . . 5–22 f. Assembly Of Retarder Stator . . . . . . . . 5–23 g. Assembly Of P3 Planetary Carrier Assembly . . . . . . . . . . . . . . . . . 5–23 h. Assembly Of Retarder Housing Assembly. . . . . . . . . . . . . . . . . . . . . . . . 5–23 i. Assembly Of The Retarder Valve Body. 5–24

5–12. P3 PLANETARY MODULE (4700 And 4800 Models) a. Disassembly . . . . . . . . . . . . . . . . . . . . . 5–16 b. Assembly . . . . . . . . . . . . . . . . . . . . . . . 5–16

5–15. RETARDER AND OUTPUT SHAFT MODULE (4700 And 4800 Models Equipped With Retarder) a. Disassembly Of Retarder Valve Body . 5–25 b. Disassembly Of Temperature Sensor . . 5–25 c. Disassembly Of Retarder Housing . . . . 5–25 d. Completion Of Retarder Housing Disassembly . . . . . . . . . . . . . . . . . . . . . 5–26 e. Assembly Of Output Shaft Assembly . 5–26 f. Disassembly Of Retarder Stator Assembly . . . . . . . . . . . . . . . . . . . . . . . . 5–26 g. Assembly Of Retarder Stator . . . . . . . . 5–26 h. Assembly Of Retarder Housing . . . . . . 5–27 i. Assembly Of Output Shaft Assembly. . 5–27 j. Completion Of Retarder Housing Assembly . . . . . . . . . . . . . . . . . . . . . . . . 5–27 k. Assembly Of Retarder Valve Body . . . 5–28

5–13. C6 ADAPTER HOUSING MODULE (4700 And 4800 Models) a. Disassembly Of Ring Gear and Hub Assembly . . . . . . . . . . . . . . . . . . . . . . . b. Disassembly . . . . . . . . . . . . . . . . . . . . . c. Disassembly Of P4 Planetary Carrier Assembly . . . . . . . . . . . . . . . . . . . . . . . d. Disassembly Of Remaining C6 Parts . . e. Assembly . . . . . . . . . . . . . . . . . . . . . . . f. Assembly Of P4 Planetary Carrier Assembly . . . . . . . . . . . . . . . . . . . . . . . g. Assembly Of C6 Clutch . . . . . . . . . . . .

5–19 5–20

5–16. REAR COVER MODULE (Models Equipped With Rear Cover, Except 4700 And 4800 Models) a. Disassembly. . . . . . . . . . . . . . . . . . . . . . 5–28 b. Disassembly Of P3 Planetary Carrier Assembly . . . . . . . . . . . . . . . . . 5–29 c. Completion Of Rear Cover Disassembly . . . . . . . . . . . . . . . . . . . . . 5–30 d. Beginning Rear Cover Assembly . . . . . 5–30 e. Assembly Of P3 Planetary Carrier Assembly . . . . . . . . . . . . . . . . . 5–30 f. Completion Of Rear Cover Assembly . . 5–31

5–14. RETARDER AND P3 PLANETARY MODULE a. Disassembly Of Retarder Valve Body . . 5–20 b. Disassembly Of Temperature Sensor . . 5–20 c. Disassembly Of Retarder Housing . . . . 5–21 d. Disassembly Of P3 Planetary Carrier Assembly . . . . . . . . . . . . . . . . . 5–22

5–17. REAR COVER AND OUTPUT SHAFT MODULE (4700 And 4800 Models Equipped With Rear Cover) a. Disassembly . . . . . . . . . . . . . . . . . . . . . 5–32 b. Disassembly Of Output Shaft Assembly . . . . . . . . . . . . . . . . . . . . . . . 5–32

5–9. MAIN SHAFT MODULE a. Disassembly . . . . . . . . . . . . . . . . . . . . . 5–13 b. Assembly (Except 4700 And 4800 Models). . . . . . . . . . . . . . . . . . . . . 5–14 c. Assembly (4700 And 4800 Models) . . . 5–14 5–10. P1 PLANETARY MODULE a. Disassembly . . . . . . . . . . . . . . . . . . . . . 5–14 b. Assembly. . . . . . . . . . . . . . . . . . . . . . . . 5–14 5–11. P2 PLANETARY MODULE a. Disassembly . . . . . . . . . . . . . . . . . . . . . 5–15 b. Assembly. . . . . . . . . . . . . . . . . . . . . . . . 5–15

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5–17 5–17 5–17 5–17 5–18



Page

c. Completion Of Rear Cover Disassembly . . . . . . . . . . . . . . . . . . . . . 5–32 d. Beginning Rear Cover Assembly . . . . . 5–32 e. Assembly Of Output Shaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . 5–33 f. Completion Of Rear Cover Assembly. . 5–33 5–18. CONTROL VALVE MODULE a. Removal Of Filters. . . . . . . . . . . . . . . . . 5–34 b. Removal Of Electrical Components And Sensors . . . . . . . . . . . . . . . . . . . . . . 5–35 c. Disassembly Of Solenoid Valve Body . 5–35 d. Disassembly Of C6 Control Valve Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–36 e. Disassembly Of Main Valve Body. . . . . . . . . . . . . . . . . . . . . . . 5–36 f. Disassembly Of Channel Plate . . . . . . . 5–37 g. Assembly Of Channel Plate . . . . . . . . . 5–37 h. Assembly Of Main Valve Body. . . . . . . 5–37 i. Assembly Of C6 Control Valve Body. . 5–38 j. Assembly Of Solenoid Valve Body. . . . 5–38 k. Installation Of Electrical Components And Sensors . . . . . . . . . . . . . . . . . . . . . . 5–38 l. Install Filters . . . . . . . . . . . . . . . . . . . . . 5–38

Section 6. TRANSMISSION ASSEMBLY 6–1. SCOPE a. Section . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1 b. Procedures . . . . . . . . . . . . . . . . . . . . . . . . 6–1 c. Illustrations . . . . . . . . . . . . . . . . . . . . . . . 6–1 d. General Information . . . . . . . . . . . . . . . . 6–1 e. Foldouts . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1 6–2. ASSEMBLY OF TRANSMISSION a. Assembly Of Main Housing Module . . . 6–1 b. Installation Of Rotating Clutch Module. . 6–1 c. Installation Of Front Support/ Charging Pump Module. . . . . . . . . . . . . . 6–2 d. Installation Of P1 Planetary Module . . . . 6–2 e. Installation Of P2 Planetary Module . . . . 6–2 f. Installation Of C5 Clutch Pack . . . . . . . . 6–2 g. Installation Of Main Shaft Module (Except 4700 And 4800 Models) . . . . . . 6–2 h. Installation Of Main Shaft Module (4700 And 4800 Models) . . . . . . . . . . . . 6–3

Paragraph

Page

i. Main Shaft Selective Shim Measurement (Close Ratio Models) . . . . 6–3 j. Main Shaft Selective Shim Measurement (Wide Ratio Models) . . . 6–4 k. Installation Of P3 Planetary Module (4700 And 4800 Models With Retarder). . 6–5 l. Installation Of C6 Adapter Housing Module (4700 And 4800 Models With Retarder). . . . . . . . . . . . . . . . . . . . . . . . . . 6–5 m. P3 Planetary Selective Shim Measurement (4700 And 4800 Models With Retarder) . . . . . . . . . . . . . . . . . . . . 6–6 n. P3 Planetary Selective Shim Measurement (4700 And 4800 Models With Rear Cover) . . . . . . . . . . . . . . . . . . 6–7 o. Installation Of Remainder Of P3 Planetary Module and C6 Adapter Housing Module (4700 And 4800 Models) . . . . . . . . . . . . 6–8 p. Installation Of Tolerance Rings Module (4700 And 4800 Models With Retarder) . . . . . . . . . . . . . . . . . . . . . . . . . 6–9 q. Installation Of Retarder Module (Except 4700 And 4800 Models) . . . . . . . . . . . . . 6–9 r. Installation Of Retarder and Output Shaft Module (4700 And 4800 Models With Retarders) . . . . . . . . . . . . . . . . . . . 6–10 s. Installation Of Rear Cover Module (Except 4700 And 4800 Models) . . . . . 6–11 t. Installation Of Rear Cover Module (4700 And 4800 Models). . . . . . . . . . . . 6–11 u. Installation Of Converter Housing Module . . . . . . . . . . . . . . . . . . . . . . . . . . 6–13 v. Installation Of Torque Converter Module . . . . . . . . . . . . . . . . . . . . . . . . . . 6–13 w. Installation Of Control Module . . . . . . . 6–16 x. Installing Integral Oil Cooler. . . . . . . . . 6–16 y. Installing Integral Retarder Sump Oil Cooler. . . . . . . . . . . . . . . . . . . . . . . . . . . 6–17 z. Installation Of Externally Mounted Parts . . . . . . . . . . . . . . . . . . . . 6–18 aa. Installation Of Power Takeoff . . . . . . . . 6–19 ab. Removal Of Transmission From Repair Stand . . . . . . . . . . . . . . . . . 6–19


xi


Page

Section 7. WEAR LIMITS AND SPRING DATA

Paragraph

Section 8. CUSTOMER SERVICE 8–1. OWNER ASSISTANCE. . . . . . . . . . . . . . . . 8–1

7–1. WEAR LIMITS DATA a. Maximum Variations . . . . . . . . . . . . . . . 7–1 b. Cleaning and Inspection . . . . . . . . . . . . . 7–1

8–2. SERVICE LITERATURE . . . . . . . . . . . . . . 8–2

7–2. SPRING DATA a. Spring Replacement . . . . . . . . . . . . . . . . 7–1 b. Inspection . . . . . . . . . . . . . . . . . . . . . . . . 7–1

xii

Page


4000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4 th GENERATION

LIST OF FOLDOUT ILLUSTRATIONS (Back Of Service Manual) CROSS-SECTION VIEWS Foldout

1 2 3 3,A 3,B 3,C

4000 Product Family Transmission (Close Ratio)—Cross Section 4500 Model (Wide Ratio) Transmission With PTO Provision—Cross Section 4000 Product Family (Close Ratio) Transmission With Retarder—Cross Section 4700 and 4800 Model Transmission—Cross Section 4700 and 4800 Model Transmission With Retarder—Cross Section 4700 and 4800 Model Transmission With Retarder and PTO Provision—Cross Section

EXPLODED VIEWS Foldout

4,A 4,B 5,A 5,B 6,A 6,B 7 8 9,A 9,B 9,C 10,A 10,B 10,C 10,D 11,A 11,B 12,A 12,B 12,C 13

Flexplate and Adapter Torque Converter Module Converter Housing Module Converter Housing Module With PTO Provision Front Support and Charging Oil Pump Module Rotating Clutch Module Main Housing Module Main Shaft Module P1 Planetary Module P2 Planetary Module P3 Planetary Module and C6 Adapter Housing Module (4700 and 4800 Models) Rear Cover and P3 Planetary Module Rear Cover and Output Shaft Module (4700 and 4800 Models) Retarder and P3 Module Retarder and Output Shaft Module (4700 and 4800 Models) Control Module Control Module Output Flange and Yoke Support Equipment Integral Retarder Sump Cooler 4000 Product Family Hydraulic Schematic—Neutral


xiii

4000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4 th GENERATION NOTES

xiv


SECTION 1—GENERAL INFORMATION 1–1.

SCOPE OF MANUAL

a. Content and Organization. This Service Manual describes overhaul procedures for 4000 Product Family transmissions with Allison 4th Generation Controls. Power takeoff (PTO) and output retarder options may be added to a base transmission model. • Detailed instructions are provided for

disassembly in Section 4, rebuild in Section 5, and reassembly in Section 6. • Part inspection instructions are in Section 3. • Wear limits and spring data are in Section 7. • Major transmission components and their

functions are explained in 3000 and 4000 Product Families Principles of Operation PO4016EN. The 4000 Product Family consists of the following transmission series and models (Figures 1–1 through 1–6): Highway Series: • 4000 HS • 4500 HS Rugged Duty Series: • 4000 RDS • 4700 RDS Emergency Vehicle Series: • 4000 EVS • 4500 EVS • 4700 EVS • 4800 EVS Motorhome Series: • 4000 MH Truck Recreational Vehicle Series: • 4000 TRV • 4500 TRV Specialty Series: • 4000 SP • 4500 SP • 4700 SP • 4800 SP Bus Series: • B 500

T 400 Series: • T 425 • T 450 • T 525 b. Illustrations 1. The text is supported with line drawings and cross-sectional views. Overhaul procedures are illustrated by line drawings. Cross-sections show the relationship of assembled parts. Cross-sections, exploded views, and a hydraulic schematic (transmission in Neutral) are on foldout pages in the back of the manual. 2. Illustrations show correct procedures for all models—including models not illustrated. c. Maintenance Information. Each task described in this manual has been successfully completed by service organizations and individuals. Not every service organization or individual possesses the required special tooling, training or experience to perform all described tasks. However, any task may be performed if the following conditions are met: 1. The organization or individual has the required knowledge of the task through: • Formal instruction at Allison Transmission

or a Distributor training facility. • On-the-job instruction by an Allison

Transmission or Distributor representative. • Experience in performing the task.

2. The work environment is suitable to prevent contamination or damage to transmission parts or assemblies. 3. Required tools and fixtures are available as shown in Section 3 of this manual. Refer to Figures 3–2 and 3–3 and Tables 3–1 and 3–2. 4. Reasonable and prudent maintenance practices are used. NOTE: Service organizations and individuals are encouraged to contact their local Allison Transmission Distributor for information and guidance on any task outlined in this manual.


1–1


PTO PROVISION (TOP RIGHT POSITION)

SHIPPING BRACKET (3)

MOUNTING PAD

FEEDTHROUGH HARNESS CONNECTOR

ENGINE SPEED SENSOR TURBINE SPEED SENSOR OUTPUT SPEED SENSOR

COOLER PORTS

FILL TUBE NAMEPLATE V07319.01.00

.

Figure 1–1. 4000 Product Family Transmission With PTO Provision (Except 4700 and 4800 Models)—Right-Rear View


MOUNTING PAD (BOTH SIDES)

PTO PROVISION (BOTTOM LEFT POSITION)

MAIN-PRESSURE TAP

COOLER PORTS

V06830.01.00

Figure 1–2. 4000 Product Family Transmission With PTO Provision (Except 4700 and 4800 Models)—Left-Rear View

1–2


GENERAL INFORMATION FILL TUBE

PTO PROVISION (TOP RIGHT POSITION) RETARDER


TORQUE CONVERTER MODULE NAMEPLATE

TURBINE-SPEED SENSOR ENGINE-SPEED SENSOR MOUNTING PAD V07320.01.00

Figure 1–3. 4000 Product Family With PTO Provision and Retarder (Except 4700 and 4800 Models)—Right-Front View

MOUNTING PAD OUTPUT-SPEED SENSOR

PTO PROVISION (BOTTOM LEFT POSITION)

RETARDER

MAIN-PRESSURE TAP COOLER PORTS ACCUMULATOR PORT

V07334.01.00

Figure 1–4. 4000 Product Family With PTO Provision and Retarder (Except 4700 and 4800 Models)—Left-Rear View


1–3

4000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4 th GENERATION BREATHER PTO PROVISION

C6 ADAPTER HOUSING

RETARDER

OUTPUT FLANGE

MOUNTING PAD

PTO PROVISION

MOUNTING PAD V07333.01.00

Figure 1–5. 4000 Product Family With PTO Provision and Retarder (4700 and 4800 Models)—Left-Rear View

PTO PROVISION (TOP RIGHT POSITION)

C6 ADAPTER HOUSING

MOUNTING PAD

INPUT SPEED SENSOR

TURBINE SPEED SENSOR FILL T UBE OUTPUT SPEED SENSOR

NAMEPLATE V07332.01.00

Figure 1–6. 4000 Product Family With PTO Provision (4700 and 4800 Models)—Right-Rear View

1–4


GENERAL INFORMATION 1–2.

SUPPLEMENTARY INFORMATION

Yellow Pages for your nearest authorized service outlet. Listings are under Transmission—Truck or Engines—Diesel.

Supplementary information will be issued, as required, if any changes occur after publication of this manual. Consult your dealer or distributor to be sure you have the latest information.

1–3.

ORDERING PARTS

a. Transmission Nameplate. The nameplate (Figure 1–7) is located on the right side of the transmission. The nameplate is imprinted with the following:

1–4.

GENERAL DESCRIPTION

Allison 4000 Product Family transmissions are a complete transmission system that includes all hardware needed for vehicle application. a. Major Modules. 4000 Product Family transmissions contain the following major modules: • Input Module • Main Housing and Gear Module

• Model number

• Control Module

• Serial number

• Output Module

• Data code

• C6 Adapter Module (4700 and 4800 models)

• TransID number

b. Unique Features. Features unique to 4000 Product Family transmissions are: configurations • Lockup clutch with torsional damper • Integral retarder (optional) • Integral oil filters, serviceable without

complete loss of transmission fluid • Adaptive electronic closed-loop controls with

LTURAL

IMP

L

MO

BIL

E , A E ROSPACE AN

RICU

T WORKERS O F

UT

O

TRANSMISSION IDENTIFICATION NUMBER

AG

EN

DATA CODE

D

EM

General Motors Corp. Indianapolis, Indiana, USA

self-diagnostic capabilities

UNITED A

b. Parts Catalog. Replacement parts are listed in the current 4000 Product Family Parts Catalog PC2456EN. Do not order by the item numbers used on exploded views in this manual. Use the Parts Catalog to determine the correct part number. Order all replacement parts from your distributor. Check the

• Three, four, five, six, or seven forward speed

ICA

Use all of these numbers when ordering replacement parts or requesting service information.

ER

(for Specialty Series vocation models)

AM

• Engineering Feature Configuration Number

00A00

ENGINEERING FEATURE CONFIGURATION NUMBER FIELD

TIDA

S/N

XXXXXXXXXX

MODEL NUMBER FIELD

SERIAL NUMBER

V09468.01.01

Figure 1–7. Transmission Nameplate


1–5

4000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4 th GENERATION 1–5.

MAJOR COMPONENTS

a. Input Module. The Input Module includes: • Torque converter • Power takeoff gearing (optional)

b. Torque Converter 1. The torque converter includes a lockup clutch and torsional damper for direct and smooth transfer of engine power. 2. Torque converter models available are: Torque Converter Model TC 521 TC 531 TC 541 TC 551 TC 561 c. Power Takeoff. Direct, engine-driven PTO gearing is available at two positions, except in the 4000 HS. d. Main Housing and Gear Module. The Main Housing and Gear Module include: • Main Housing • Oil pump charging system • Three planetary gear sets

(four for 4700 and 4800 models) • Two rotating clutches • Three stationary clutches (four for 4700 and 4800 models) e. Range Clutches. Range clutches are multipledisc, wet-type clutches. Exhaust backfill pressure is used to reduce fill time for quick response and smooth shifts. f. Control System. The control system is capable of recognizing hydraulic and electronic conditions that are not within the operating limits of the programmed calibration. Some out-of-limit conditions can be corrected by the control system. All out-of-limit condition diagnostic codes are stored for later retrieval by a technician. The Electronic Control System includes: • Transmission Control Module (TCM)

1–6

• Sensors • Wiring harness (customer-furnished)

• Engine adaptation

• Control module

• Shift selector

The TCM is a high-speed digital computer that receives information from the sensors and shift selector. This information is processed and shift commands are sent to the control module for range selection. g. Transmission Fluid Filters. Two disposable external-access filters are part of the control module. Each filter is in a separate cavity which permits removal and replacement without complete loss of transmission fluid. h. Transmission Fluid Coolers. The 4000 Product Family has provision for remote or integral transmission fluid coolers. i. C6 Adapter Housing Module. The C6 adapter housing module is unique to the 4700 and 4800 models. It provides a seventh range and is located between the main housing and rear cover/retarder. j. Rear Cover. A rear cover is standard equipment on the 4000 Product Family. The output shaft can be provided with a variety of companion flanges or yokes. k. Output Retarder and Output Flange. The optional output retarder module replaces the standard rear cover. An output flange or yoke is available for use with the retarder.

1–6. BUS EVS HS MH RDS SP TRV 7 or 8 5 0

4000 PRODUCT FAMILY MODEL DESIGNATION CODE – – – – – – – – – –

Bus Series Emergency Vehicle Service Highway Series Motorhome Series Rugged Duty Series Specialty Series Truck Recreational Vehicle Series Widest Ratio Coverage (WRC) Wide Ratio (WR) Close Ratio (CR)

The following table lists the standard (STD) and optional (OPT) features of each 4000 Product Family model code designations:


GENERAL INFORMATION

CR/WR

Maximum Forward Ranges

PTO

Retarder

Deep Sump

Shallow Sump

OLS

4000 EVS

CR

6

STD

OPT

STD

OPT

STD

4000 HS

CR

6

N/A

OPT

STD

N/A

STD

4000 MH

CR

6

OPT

OPT

STD

OPT

STD

4000 RDS

CR

6

STD

OPT

STD

N/A

STD

4000 SP

CR

6

STD

OPT

STD

OPT

STD

4000 TRV

CR

6

OPT

OPT

STD

N/A

STD

4500 EVS

WR

6

STD

OPT

STD

OPT

STD

4500 HS

WR

6

N/A

OPT

STD

N/A

STD

4500 RDS

WR

6

STD

OPT

STD

N/A

STD

4500 SP

WR

6

STD

OPT

STD

OPT

STD

4700 EVS

WR

7

STD

OPT

STD

OPT

STD 1

4700 RDS

WRC

7

STD

OPT

STD

N/A

STD 1

4700 SP

WRC

7

STD

OPT

STD

N/A

STD

4800 EVS

WRC

7

STD

OPT

STD

OPT

STD 1

4800 SP

WRC

7

STD

OPT

STD

N/A

STD

B 500

CR

6

OPT

OPT

STD

OPT

STD

T 425

CR

5

OPT

OPT

STD

OPT

STD

T 450

CR

5

OPT

OPT

STD

OPT

STD

T 525

CR

5

OPT

OPT

STD

OPT

STD

Vocational Model

1—OLS not available on 7-speed models with retarders.

1–7.

EXPLODED (DISASSEMBLED) VIEWS

Exploded views illustrate 4000 Product Family transmission parts in relation to each other. The parts numbering system in the exploded views is used in all procedures described in the text.

1–8.

DIAGNOSIS

NOTE: Refer to Allison 4th Generation Controls Troubleshooting Manual (TS3989EN) for in-depth troubleshooting procedures.

a. Before Starting. Before attempting to repair the transmission, the faulty condition and its probable cause should be identified. b. CHECK TRANS Light. Continued illumination of the CHECK TRANS light during vehicle operation indicates the TCM has signaled a diagnostic code. At start-up, the CHECK TRANS light will briefly illuminate to indicate that the light is functioning properly. NOTE: The Strip Pushbutton Shift Selector has no display or diagnostic capabilities. Use the Allison DOC™ For PC–Service Tool to display diagnostic trouble codes.


1–7

4000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4 th GENERATION c. Entering Diagnostic Mode 1. Pushbutton Shift Selector — When Oil Level Sensor (OLS) is present: Press the ↑ (Up) and ↓ (Down) arrow keys twice simultaneously. Diagnostics will be displayed immediately. The display will list the diagnostic codes logged by position (d1, d2, d3, etc.). — When OLS is not present: Press the ↑ (Up) and ↓ (Down) arrow keys simultaneously. The display will list the diagnostic codes logged by position (d1, d2, d3, etc.). 2. Lever Shift Selector — When OLS is not present—Press the DISPLAY MODE button. Diagnostics will be displayed immediately. — When OLS is present—Press the DISPLAY MODE button twice to enter Diagnostic Mode. The display will list the diagnostic codes logged by position (d1, d2, d3, etc.). d. Diagnostic Codes. Diagnostic codes can be displayed on the display portion of the shift selector or by using the Allison DOC™ For PC–Service Tool. A diagnostic code is either active or historical. An active code is any code that is current in the TCM decisionmaking process. Historical codes are codes that are retained in the TCM memory and will not necessarily affect the TCM decision-making process. Active codes are indicated on the shift selector by the MODE ON indicator. e. Displaying Diagnostic Codes. Press and release the MODE button to sequentially display the logged diagnostic codes. f. Diagnostic Code Displays. The code list position (d1, d2, d3, d4, and d5) is the first item displayed, followed by the diagnostic trouble code (DTC). The following example shows how DTC P0722 is displayed on pushbutton and lever shift selectors: SELECT

MONITOR

d

1 P

1–8

0

7

2

2

The display cycles continuously until the next code list position is accessed by pressing the MODE button. When all codes have been displayed by pressing the MODE button, the first code will be redisplayed. Any log position not containing a diagnostic code will display “– –” at the DTC position. No codes are logged after a “– –” display. g. Exiting Diagnostic Mode 1. Press the same buttons used to enter the diagnostic mode. 2. Select any range. The transmission will enter the selected range if the range is not inhibited. 3. Turn off the ignition switch. 4. The TCM diagnostic mode is exited automatically after approximately two minutes have elapsed without an operator input.

1–9.

PRESERVATION AND STORAGE

a. Storage (New Transmissions, Before Installation). New transmissions are filled with transmission fluid and drained before shipment. The residual fluid in the transmission provides adequate protection to safely store the transmission without further treatment for one full year if stored indoors, in conditions of normal climate, and with all shipping plugs installed. b. Preservation Methods. When the transmission is stored or inactive for an extended period (one or more years), specific preservation methods are required to prevent damage from rust, corrosion, and organic growth in the transmission fluid. Preservation methods described are for storage with or without transmission fluid and in or out of a vehicle. c. One Year Storage (Without Fluid) 1. Drain the transmission fluid. 2. Remove the breather and spray 30 ml (one ounce) of VCI #10 (or equivalent) into the transmission through the breather hole. Re-install the breather. Also, spray 30 ml (one ounce) through the fill tube hole. 3. Seal all openings and the breather with moisture-proof tape.


GENERAL INFORMATION 4. Coat all exposed, unpainted surfaces with preservative grease such as petrolatum (MIL-C-11796, Class 2).

8. Coat all exposed, unpainted surfaces with preservative grease such as petrolatum (MIL-C-11796), Class 2.

5. If additional storage time is required, repeat Steps (2) through (4) at yearly intervals.

9. If additional storage time is required, repeat Steps (2) through (8) at yearly intervals, except, it is not necessary to drain the transmission each year. Just add VCI #10 and Biobor® JF (or equivalents).

d. One Year Storage (With Fluid) 1. Drain the fluid and replace the oil filter elements. 2. Fill the transmission to operating level with a mixture of one part VCI #10 (or equivalent) to 30 parts transmission fluid. Add 3 ml of Biobor® JF (or equivalent) for each 10 liters (1⁄ 4 teaspoon per gallon) of fluid in the system. NOTE: When calculating the amount of Biobor® JF required, use the total volume of the system, not just the quantity required to fill the transmission. Include external lines, filters, and the cooler. 3. Operate the transmission in N (Neutral) for approximately five minutes at 1500 rpm. 4. Make sure the transmission shifts through all ranges and the lockup clutch activates. 5. Continue operating the transmission in neutral at 1500 rpm until normal operating temperature is reached.

CAUTION: If the unit does not have a converter-out temperature gauge, do not stall the converter.

6. If normal operating temperature is less than 107°C (225ºF), shift the transmission to forward range and stall the converter. Do not exceed 107°C (225ºF). 7. As soon as the transmission is cool enough to touch, seal all openings and the breather with moisture-proof tape.

1–10. RESTORING TRANSMISSION TO SERVICE CAUTION: Whenever a transmission is overhauled or exchanged, the Transmission Control Module (TCM) must be “RESET TO UNADAPTED SHIFTS”. This causes the TCM to erase previous adaptive information and begin to adapt in Fast Adaptive Mode from the base calibration. Use the Allison DOC™ For PC–Service Tool and select “RESET UNADAPTED SHIFTS”. Follow the instructions in the Allison DOC™ For PC– Service Tool User Guide GN3433EN to accomplish the reset. a. Transmission Exterior. Wash all external grease from the transmission with mineral spirits. b. Sealed Breather and Openings. Remove all tape from openings and the breather. c. New Transmissions. If the transmission is new, drain the residual preservative oil. Refill the transmission to the proper level with an Allisonapproved transmission fluid. Refer to Paragraph 2–10. d. Stored Without Fluid. If the transmission was prepared for storage without fluid, drain the residual fluid and replace the oil filter elements. Refill the transmission to the proper level with an Allisonapproved transmission fluid. Refer to Paragraph 2–10. e. Stored With Fluid. If the transmission was prepared for storage with fluid, it is not necessary to drain and refill the transmission with new transmission fluid. Check for proper fluid level. Add or drain transmission fluid, as required, to obtain the proper level.


1–9

4000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4 th GENERATION 1–11. ELECTROMAGNETIC/RADIO FREQUENCY INTERFERENCE All electrical and electronic systems generate electromagnetic fields that can interfere with other electronic systems. Allison Transmission’s electronic transmission controls comply with Federal Communications Commission (FCC) regulations and other guidelines concerning emitted radio frequency interference for transportation electronics. Some radio-telephone or two-way communications radios (land-mobile radio), or the manner in which they are installed, can be affected by other vehicle components or adversely affect vehicle operation. Manufacturers and installers of EMI/RFI emitting equipment are responsible for adhering to FCC regulations and other guidelines concerning emitted radio frequency interference for transportation electronics. Radio or other two-way communication antenna, power, or ground leads near the transmission wiring harness,

control devices, or power leads may create or be subject to electromagnetic interference (EMI) from the transmission control system. Refer to the Allison 4th Generation Controls Troubleshooting Manual (TS3989EN) for detailed instructions regarding EMI problems.

1–12. OPERATING INSTRUCTIONS Detailed transmission operation information is in the 3000 and 4000 Product Families Principles of Operation PO4016EN manual or in vocational model Operator’s Manual. Refer to the latest revision.

1–13. SPECIFICATIONS AND DATA The following specifications and data provide a quick reference to the major characteristics of the transmission.

Table 1–1. Specifications and Data Chart* GEAR DATA: Type

Planetary helical, constant mesh

Range

Close-Ratio†

Wide-Ratio†

Widest-Ratio Coverage†

First . . . . . . . . . . . . . . . . . . . . . . . . .

3.51:1

4.70:1

7.63

Second . . . . . . . . . . . . . . . . . . . . . . .

1.91:1

2.21:1

3.51

Third . . . . . . . . . . . . . . . . . . . . . . . .

1.43:1

1.53:1

1.91

Fourth . . . . . . . . . . . . . . . . . . . . . . .

1.00:1

1.00:1

1.43

Fifth . . . . . . . . . . . . . . . . . . . . . . . . .

0.74:1

0.76:1

1.00

Sixth. . . . . . . . . . . . . . . . . . . . . . . . .

0.64:1

0.67:1

0.74

Seventh . . . . . . . . . . . . . . . . . . . . . .

—

—

0.64

Reverse . . . . . . . . . . . . . . . . . . . . . .

–4.80:1

–5.55:1

–4.80:1

ENGINE-DRIVEN POWER TAKEOFF PROVISION: Positions . . . . . . . . . . . . . . . . . . . . . 8 o’clock and 1 o’clock (viewed from rear) PTO Unit Ratings at the Transmission: PTO Drive Gear . . . . . . . . . . . . . Maximum torque through one pad: 930 N·m (685 lb ft) Maximum torque through both pads simultaneously: 1595 N·m (1175 lb ft) NOTE: No more than 930 N·m (685 lb ft) allowed through any single pad.

* All data and specifications are subject to change without notice. † Gear ratios do not include torque converter multiplication.

1–10


GENERAL INFORMATION Table 1–1. Specifications and Data Chart* (cont’d) HYDRAULIC SYSTEM: Fluid type . . . . . . . . . . . . . . . . . . . . TranSyndTM, MIL-PRF-2104, MIL-PRF-46167, MIL-PRF-21260, DEXRON®-III, C-4 (refer to Paragraph 2–10.) Filters, main and lube . . . . . . . . . . . Dual integral, replaceable cartridge type 4000 PRODUCT FAMILY SIZES: With PTO drive

Without PTO drive

Length (transmission mounting face to rear of output shaft) without retarder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 854.0 mm (33.62 inch)

781.1 mm (30.75 inch)

with retarder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 845.6 mm (33.29 inch)

772.6 mm (30.42 inch)

Length (transmission mounting flange to output flange 798.7 mm (31.45 inch) mounting face on P3 carrier) . . . . . . . . . . . . . . . . . . . . . . . . . .

725.7 mm (28.57 inch)

Depth (standard sump, centerline to lowest point) . . . . . . . . . 374.7 mm (14.75 inch)

374.7 mm (14.75 inch)

Dry weight—add 16.0 kg (35.0 lb) if integral cooler is used with retarder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 439 kg (968 lb)

411 kg (906 lb)

without retarder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405 kg (893 lb)

377 kg (831 lb)

with retarder and integral retarder sump cooler. . . . . . . . . . 469 kg (1032 lb)

441 kg (970 lb)

4700/4800 Models With PTO drive

4700/4800 Models Without PTO drive

Length (transmission mounting face to rear of output shaft) with retarder or rear cover . . . . . . . . . . . . . . . . . . . . . . . . . . 1104.1 mm (43.47 inch) 966.3 mm (38.04 inch) Depth (standard sump, centerline to lowest point) . . . . . . . . . 378.2 mm (14.89 inch)

378.2 mm (14.89 inch)

Dry weight—add 16.0 kg (35.0 lb) if integral cooler is used with retarder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 554 kg (1324 lb)

527 kg (1162 lb)

without retarder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 521 kg (1149 lb)

493 kg (1087 lb)

* All data and specifications are subject to change without notice.


1–11


1–12


SECTION PREVENTIVE 2—PREVENTIVE MAINTENANCE MAINTENANCE 2–1.

SCOPE

Proper care and regular maintenance is necessary for the transmission to meet its duty requirements. Perform the maintenance procedures described in this section on a regular basis to prevent premature transmission or support equipment failure. Allison transmissions are manufactured to provide long-term, efficient service in their designed applications.

2–2.

PERIODIC INSPECTION AND CARE

a. Exterior Cleaning and Inspection

level is too high, the fluid aerates causing the transmission to shift erratically and overheat. b. Oil Level Sensor. The optional oil level sensor (OLS) allows the operator to determine the fluid level from either a full-function pushbutton or a lever shift selector. There is no fluid level reading capability for an Allison 4th Generation Controls strip-type pushbutton selector; use the Allison DOC™ For PC– Service Tool to obtain fluid level data from the OLS.

NOTE: • The oil level sensor compensates for transmission

fluid temperatures from 60–104°C (140–220°F). Any temperature below 60°C (140°F) or above 104°C (220°F) will result in an “Invalid for Display” condition.

CAUTION: DO NOT pressure-wash the transmission electrical connectors. Water and detergent cause the electrical contacts to corrode and become faulty. 1. Clean and inspect the exterior of the transmission at regular intervals. Severity of service and operating conditions determine the frequency of inspections. 2. Inspect the transmission for: • Loose bolts—transmission and mounting

components. • Fluid leaks—repair immediately. • Loose, dirty, or improperly adjusted throttle

• To accurately determine the transmission

fluid level with the dipstick, the transmission fluid must be at normal operating temperature (71–93°C; 160–200°F). c. Electronic Controls and Protection Circuits. 4000 Product Family transmission electronic controls and protection circuits alert the operator to a transmission malfunction or the need for service. The electronic controls and protection circuits do not replace regular, manual, fluid level checks. Confirm the fluid level at the intervals specified in vehicle service instructions.

sensor linkage. • Damaged or loose fluid hoses.

2–4.

• Worn, frayed, or improperly routed

electrical harnesses. • Bent, worn or out-of-phase driveline

U-joints and slip fittings.

2–3.

IMPORTANCE OF PROPER FLUID LEVEL

a. Transmission Fluid. Transmission fluid cools, lubricates, and transmits hydraulic power. Always maintain the correct fluid level. If the level is too low, the torque converter and clutches do not receive enough fluid and the transmission overheats. If the

ELECTRONIC FLUID LEVEL CHECK (WHEN AN OPTIONAL OLS IS PRESENT—FULLFUNCTION PUSHBUTTON OR LEVER SHIFT SELECTORS)

NOTE: The Allison 4th Generation Controls full-function pushbutton and lever shift selectors can display two characters at one time. One character is displayed under the SELECT label and one under the MONITOR label.


2–1

4000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4 th GENERATION a. Fluid Level Check Procedure 1. Park the vehicle on a level surface and shift to N (Neutral). Apply the parking brake. 2. To enter oil level display mode: • Pushbutton shift selector—simultaneously

press the ↑ (Up) and ↓ (Down) arrow buttons once.

additional quarts of fluid will bring the fluid level within the middle of the “O K” zone. 5. High fluid level (o L H I 0 #) is reported when “o L” is displayed, followed by “H I” and a number. “H I” indicates high fluid level and the number indicates the number of quarts the transmission is overfilled. Example: “O L H I 0 1” indicates one quart of fluid above the full level.

• Lever shift selector—press the DISPLAY

MODE pushbutton once.

CAUTION:

NOTE: The TCM may delay the fluid level check until the following conditions are met: • The fluid temperature is above 60°C (140°F)

or below 104°C (220°F). • The transmission is in neutral. • The vehicle has been stationary for approxi-

mately two minutes to allow the fluid to settle. • The engine is at idle.

Indication of a delayed fluid level check for Allison 4th Generation Controls is a flashing display under SELECT label and a digit countdown from 8 to 1 under MONITOR label. 3. Correct fluid level is reported when “o L” is displayed (o L” indicates the Oil Level Check Mode), followed by “o K o K”. The “o K” display indicates the fluid level is within the correct fluid level zone. The sensor display and the transmission dipstick may not agree exactly because the oil level sensor compensates for fluid temperature. Example: “o L o K o K” indicates correct fluid level. 4. Low fluid level is reported when “o L” is displayed followed by “L o” and a number. “L o” indicates a low fluid level and the number indicates the number of quarts of fluid the transmission requires. Confirm a low fluid level condition by making a manual fluid level check. Example: “o L L o 0 2” indicates two

2–2

A low or high fluid level causes overheating and irregular shift patterns and if not corrected, can damage the transmission. 6. Invalid for Display condition is reported when “o L” is displayed, followed by “– –” and a number. The displayed number is a fault code, and indicates improper conditions or a system malfunction. Example: “o L – – 70” indicates an Invalid for Display condition and fault code 70. 7. Invalid for Display is activated when conditions do not allow the fluid level to be determined. Review the following codes and conditions, and correct as necessary. If these conditions cannot be corrected, contact the nearest distributor or dealer in your area (look in the telephone directory for the Allison Transmission service outlet nearest you.) Code

Cause of Code

“OL – – 0X” — Settling time too short “OL – – 50” — Engine speed (rpm) too low “OL – – 59” — Engine speed (rpm) too high “OL – – 65” — N (Neutral) must be selected “OL – – 70” — Sump oil temperature too low “OL – – 79” — Sump oil temperature too high “OL – – 89” — Output shaft rotation “OL – – 95” — Sensor failure


PREVENTIVE MAINTENANCE NOTE:

is not clogged. If readings are still inconsistent, contact your nearest Allison distributor or dealer.

Report sensor failure to a distributor or dealer in your area. Refer to the Allison Transmission website www.allisontransmission.com or a telephone directory for the Allison Transmission distributor or dealer nearest you.

2–6.

8. To exit the oil level display mode: • Pushbutton shift selector—press any

pushbutton on the shift selector. • Lever shift selector—press the DISPLAY MODE button twice.

2–5.

MANUAL FLUID LEVEL CHECK PROCEDURE

COLD CHECK (Figure 2–1)

CAUTION: DO NOT start the engine until the presence of sufficient transmission fluid has been confirmed. Remove the transmission fluid dipstick and be sure the static fluid level is near the HOT FULL mark. a. Purpose. The purpose of the Cold Check is to determine if the transmission has enough fluid to be operated safely until a Hot Check can be made. b. Cold Check Procedure

WARNING! If you leave the vehicle and the engine is running, the vehicle can move suddenly and you or others could be injured. If you must leave the engine running, do not leave the vehicle until you have completed all of the following procedures:

1. Park the vehicle on a level surface, chock the wheels, and apply the parking brake.

• Be sure the engine is at low idle (500–800 rpm).

2. Run the engine at idle (500–800 rpm) for at least one minute with the transmission in N (Neutral). Shift to D (Drive), then shift to R (Reverse) to clear the hydraulic system of air. Then, shift to N (Neutral) and allow the engine to idle.

• Apply the parking brake and emergency brakes and make sure they are properly engaged.

3. With the engine running, remove the dipstick from the tube and wipe clean.

• Put the transmission in N (Neutral).

• Chock the wheels and take any other steps necessary to keep the vehicle from moving. a. Preparation. Clean all dirt from around the end of the fluid fill tube before removing the dipstick. Do not allow dirt or foreign matter to enter the transmission. Dirt or foreign matter in the hydraulic system may clog passages and cause undue transmission part wear or sticking valves. b. Consistency of Readings. Always test the fluid level reading at least twice using the Hot Check and Cold Check procedures in Paragraphs 2–6 and 2–7. Consistency (repeatable readings) is important to maintaining proper fluid level. If inconsistent readings persist, inspect the transmission breather to be sure it

4. Insert the dipstick into the tube and remove. Read the fluid level. Repeat the procedure to verify the reading. 5. If the fluid level is within the “COLD CHECK” band, the transmission can be operated until the fluid is hot enough to perform a Hot Check. If the fluid level is not within the “COLD CHECK” band, add or drain as necessary to bring the fluid level to the middle of the “COLD CHECK” band. 6. Perform a Hot Check at the first opportunity after normal operating temperature is reached—71–93°C (160–200°F).


2–3


HOT CHECK (Figure 2–1)

WARNING! If you leave the vehicle and the engine is running, the vehicle can move suddenly and you or others could be injured. If you must leave the engine running, do not leave the vehicle until you have completed all of the following procedures:

4. Insert the dipstick into the tube and remove. Read the fluid level. Repeat the procedure to verify the reading. 5. If the fluid level is not within the “HOT CHECK” band, add or drain as necessary to bring the fluid level within the band. Safe operating level is within the “HOT CHECK” band on the dipstick (refer to Figure 2–1).

• Put the transmission in N (Neutral). • Be sure the engine is at low idle (500–800 rpm). • Apply the parking brake and emergency brakes and make sure they are properly engaged. • Chock the wheels and take any other steps necessary to keep the vehicle from moving.

CAUTION: An accurate fluid level check cannot be made unless the engine is idling (500–800 rpm) in N (Neutral), the transmission fluid is at the proper temperature, and the vehicle is on a level surface. a. Purpose. The purpose of the Hot Check is to determine if the transmission has enough fluid to be operated safely.

KEEPING FLUID CLEAN

CAUTION: Containers or fillers that have been used for antifreeze or engine coolant solution must NEVER be used for transmission fluid. Antifreeze and coolant solutions contain ethylene glycol which, if put into the transmission, can cause clutch plate failure. Prevent foreign material from entering the transmission by using clean containers, fillers, etc. Lay the dipstick in a clean place while filling the transmission. Calibration level marking locations with respect to transmission control module splitline and fill tube SCALE NONE

1. Operate the transmission in D (Drive) range until normal operating temperature is reached: 71–93°C (160–200°F)

HOT ADD

DIMENSION A SEE CHART BELOW

• Sump temperature—

DIMENSION C

If a transmission temperature gauge is not present, determine fluid level when the engine water temperature gauge has stabilized and the transmission has been operated under load for at least one hour. 2. Park the vehicle on a level surface and shift to N (Neutral). Apply the parking brake and chock the wheels. Allow the engine to idle (500–800 rpm). 3. With the engine running, remove the dipstick from the tube and wipe clean.

2–4

COLD ADD

82–104°C (180–220°F)

132.6 mm (5.22 in.)

COLD FULL

DIMENSION B

• Converter-out temperature—

FILL TUBE HOT FULL

b. Procedure

2–8.

13.8 mm (0.54 in.) REFERENCE DIMENSION D DETERMINED BY TRANSMISSION INSTALLATION CONTROL MODULE SPLITLINE DIMENSION DIMENSION DIMENSION

A

B

C

106.7 mm (4.20 in.)

76.2 mm (3.00 in.)

66.0 mm (2.60 in.)

V02511.00.01

Figure 2–1. Fluid Dipstick Markings


PREVENTIVE MAINTENANCE 2–9.

FLUID RECOMMENDATIONS

Table 2–1. Transmission Fluid Preheating Requirements

a. Fluid Type 1. The hydraulic fluids (oils) used in Allison transmissions directly affect transmission performance, reliability, and durability. Recommended fluids for 4000 Product Family applications are TranSyndTM, or other TES-295 fluid, and DEXRON®-III. Type C-4 fluids are also approved. 2. Some DEXRON®-III fluids are also qualified as Type C-4 fluids. To be sure the fluid is qualified for use in Allison transmissions, look for a DEXRON®-III or Type C-4 fluid license, or approval numbers on the fluid container, or consult the lubricant manufacturer. Fluid types such as Type F, and universal farm fluids may or may not be properly qualified to use in your Allison transmission. Consult your Allison Transmission dealer or distributor before using any fluid types except those fluids qualified for use in Allison transmissions.

CAUTION: Disregarding minimum fluid temperature limits can result in transmission malfunction or reduced transmission life. 3. When choosing the optimum viscosity grade of fluid to use, duty cycle, preheat capabilities, and/or geographical location must be taken into consideration. Table 2–1 lists the minimum fluid temperatures at which the transmission may be safely operated. Preheat with auxiliary heating equipment or by running the equipment or vehicle with the transmission in N (Neutral) for a minimum of 20 minutes before attempting range operation.

Viscosity Grade

SAE 0W-20* or TranSyndTM DEXRON®-III SAE 10W SAE 15W-40W SAE 30W SAE 40W

(Ambient Temperature Below Which Preheat Is Required) ºC ºF

–30

–22

–25 –20 –15 0 10

–13 –4 5 32 50

* Arctic as defined by MIL-PRF-46167B (was MIL-L-46167)

2–10. FLUID AND FILTER CHANGE INTERVALS CAUTION: Transmission fluid and filter change frequency is determined by the severity of transmission service. More frequent changes may be necessary than recommended in the general guidelines when operating conditions create high levels of contamination or overheating. a. Fluid and Filter Changes. Change the main filter after the first 8000 km (5000 miles) then follow the recommended fluid and filter change intervals. Table 2–2 is given only as a general guide for fluid and filter change interval. Local conditions, severity of operation or duty cycle may require more or less frequent fluid change intervals that differ from the published recommended fluid change intervals of Allison Transmission. Transmission protection and fluid change intervals can be optimized by the use of fluid analysis. Filters must be changed at or before recommended intervals.


2–5

2–6

Main 12,000 Miles (20 000 km) 6 Months 500 Hours

Internal Overhaul

Lube/ Auxiliary 12,000 Miles (20 000 km) 6 Months 500 Hours Fluid 25,000 Miles (40 000 km) 12 Months 1000 Hours

Main 25,000 Miles (40 000 km) 12 Months 1000 Hours

Internal Overhaul

GENERAL VOCATION Filters Lube/ Auxiliary 25,000 Miles (40 000 km) 12 Months 1000 Hours


Overhaul

75,000 Miles (120 000 km) 36 Months 3000 Hours



Overhaul

50,000 Miles (80 000 km) 24 Months 2000 Hours Overhaul






Local conditions, severity of operation or duty cycle may require more or less frequent fluid change intervals that differ from the published recommended fluid change intervals of Allison Transmission. Transmission protection and fluid change intervals can be optimized by the use of fluid analysis. Filters must be changed at or before recommended intervals.

Severe Vocation: All Retarders, On/Off Highway, Refuse, Transit, and Intercity Coach with duty cycle greater than one (1) stop per mile. General Vocation: Intercity Coach with duty cycle less than or equal to one (1) stop per mile and all other vocations.

Overhaul

Schedule 3. Recommended Fluid and Filter Change Intervals (TranSynd™/TES 295 Fluid)

2 inch Control Module (1.75 inch approximately)—Requires Filter Kit P/N 29540493


NOTE: Change fluid/filters after recommended mileage, months, or hours have elapsed, whichever occurs first.



Schedule 2. Recommended Fluid and Filter Change Intervals (TranSynd™/TES 295 Fluid)

4 inch Control Module (3.5 inch approximately)—Requires Filter Kit P/N 29540494

Flushing Machines are not recommended due to inconsistencies in removing 100 percent of the used fluid.

NOTE: The following recommendations in Schedule 2 are based upon the transmission containing 100 percent of TranSynd™ fluid. 4000 Product Family Filter change intervals in Schedule 2 and 3 are only valid with the use of Allison Transmission Gold series filters.

Fluid 12,000 Miles (20 000 km) 6 Months 500 Hours

SEVERE VOCATION Filters

Schedule 1. Recommended Fluid and Filter Change Intervals (Non-TranSynd™/Non-TES 295 Fluid)

4000 Product Family

Table 2–2. Transmission Fluid and Filter Change

4000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4th GENERATION

PREVENTIVE MAINTENANCE

b. Fluid Analysis. Transmission protection and fluid change intervals can be optimized by monitoring fluid oxidation according to the tests and limits shown in Table 2–3. Consult your local telephone directory for fluid analysis firms. For consistent and accurate fluid analysis, use only one fluid analysis firm. Refer to the Technician’s Guide for Automatic Transmission Fluid, GN2055EN, for additional information. Table 2–3. Fluid Oxidation Measurement Limits Test

Limit

Viscosity

±25% change from new fluid

Total Acid Number

+3.0* change from new fluid

* mg of KOH to neutralize a gram of fluid.

2–11. FLUID CONTAMINATION CAUTION:

immediate action to prevent malfunction and possible serious damage. The transmission must be completely disassembled, inspected, and cleaned. Remove all traces of the coolant and varnish deposits resulting from engine coolant contamination. Replace friction clutch plates contaminated with engine coolant. c. Metal

CAUTION: If excessive metal contamination has occurred, replace the oil cooler and visually inspect all bearings in the transmission. Metal particles in the fluid (except for the minute particles normally trapped in the oil filter) may indicate internal transmission damage. When these particles are found in the sump, the transmission must be disassembled and closely inspected to find the source. Metal contamination requires complete transmission disassembly. Clean all internal and external hydraulic circuits, cooler, and all other areas where the particles could lodge.

Contaminated fluid can leave the oil cooler contaminated. The cleanliness of the oil cooler affects the cleanliness of the transmission fluid. If there is any doubt about the cleanliness of the cooler, replace the cooler.

2–12. FLUID AND FILTER CHANGE PROCEDURE

a. Water

NOTE: If only filters are being replaced, do not drain the fluid.

1. At each fluid change, examine the drained fluid for evidence of dirt or water. A normal amount of condensation will appear in the fluid during operation. 2. Obvious water contamination of the transmission fluid requires inspecting and pressure testing the cooler (heat exchanger) for leaks between the water and fluid areas. Transmission fluid in the water side of the cooler (heat exchanger) is another sign of a leak. NOTE: Cooler water can also be contaminated by engine oil; be sure to locate the correct source of cooler water contamination. b. Engine Coolant. Engine coolant (ethylene glycol) in the transmission hydraulic system requires

a. Drain Fluid

WARNING! Avoid contact with the hot fluid or the hot sump when draining transmission fluid. Direct contact with the hot fluid or the hot sump may result in bodily injury. 1. Drain the transmission when the fluid is at operating temperature—71–93°C (160–200°F). Hot fluid flows quicker and drains more completely. 2. Remove the drain plug from the control module and allow the fluid to drain into a suitable container. 3. Examine the fluid Paragraph 2–11.


as

described

in

2–7

4000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4 th GENERATION b. Replace Filters (Figure 2–2)

4. Install six bolts 6 into each cover 5 and tighten them to 51–61 N·m (38–45 lb ft).

CAUTION:

c. Refill Transmission

Do not interchange filters for the deep and shallow sump. Installation of the wrong filter can cause damage to the transmission. 1. To replace the oil filters remove twelve bolts 6, two filter covers 5, two gaskets 4, two O-rings 3, two O-rings 2, and two filters 1 from the bottom of the control module.

1. If removed, inspect the drain plug. Replace the O-ring. Install the drain plug and tighten it to 25–32 N·m (18–25 lb ft). 2. After refill, determine if fluid level is correct (refer to Paragraphs 2–5 through 2–7). Table 2–4 shows typical transmission fluid capacity. NOTE:

2. When reinstalling parts lubricate and install new O-rings 2 and 3 on each cover 5. Lubricate O-ring inside filter 1 and push filter onto each cover 5. Install new gasket 4 on each cover 5 and align holes in gasket with holes in cover.

CAUTION: Do not use the bolts to draw filter covers to the sump. This can damage the covers, seals, or sump. 3. Install filter 1 and cover 5 assemblies into the filter compartment. Index each filter/cover assembly to the holes in the channel plate/ sump. Push the filter/cover assemblies in by hand to seat the seals.

LUBE

MAIN

The quantity of refill fluid will be less than the transmission fluid capacity due to fluid remaining in the external circuits and transmission cavities. Use Table 2–4 as a guideline for determining fluid quantity during refill. Table 2–4. Transmission Fluid Capacity 4000 Product Family Item Being Filled

Capacity*

4.00 inch Sump

PTO Provision

48.0 liters 51.0 quarts

4.00 inch Sump

No PTO Provision


2.00 inch Sump

PTO Provision


2.00 inch Sump

No PTO Provision


Additional Fill For Cooler* Direct-mount

Non-retarder

1.0 liter 1.1 quart

Additional Fill For Retarder Accumulator* 7 8

1 2 3 4 5 6

9

Remote

Accumulator

0.5 liter 0.5 quart

* Does not include hoses or fittings. LUBE

2–13.

MAIN

BREATHER

V07321.02.00

Figure 2–2. Filter Change 2–8

a. Location and Purpose. The breather is located on top of the transmission converter housing. It serves


PREVENTIVE MAINTENANCE to prevent air pressure buildup within the transmission and must be kept clean and open.

preparations have been made before conducting the transmission stall test. 1. The manufacturer concurs with performing a full-throttle transmission stall test.

b. Maintenance 1. The amount of dust and dirt encountered will determine the frequency of breather cleaning. Use care when cleaning the transmission exterior. Spraying steam, water, or cleaning solution directly at the breather can force the water or cleaning solution into the transmission.

2. The engine programmable parameter for 0 rpm transmission output speed is set higher than the value expected at transmission stall speed.

2. Always use a properly sized wrench to remove or replace the breather. Pliers or a pipe wrench can crush or damage the breather’s stem and produce metal chips which could enter the transmission.

5. Make sure the engine air induction system and exhaust system have no restrictions.

2–14. TRANSMISSION STALL TEST AND NEUTRAL COOL-DOWN CHECK a. Purpose. Stall testing is performed to determine if a vehicle performance complaint is due to an engine or transmission malfunction. Stall testing is a troubleshooting procedure only—never perform a stall test as a general examination or during routine maintenance. Transmission stall speed is the maximum engine rpm attainable when the engine is at full throttle and the torque converter turbine is not moving, or “stalled.” After a transmission stall test, compare the actual full throttle engine speed at torque converter turbine stall with specifications established by the vehicle manufacturer. NOTE: Engine speed data can be obtained from the vehicle manufacturer, or from the equipment dealer or distributor. Some engine manufacturers provide a programmable parameter to limit engine speed when the transmission output speed is 0 rpm, such as at a stop. This parameter should be set to a higher value than the expected transmission stall speed before performing a stall test.

b. Stall Testing Preparation. If a transmission stall test is to be performed, make sure the following

3. The vehicle is in an area in which a transmission stall test can be safely performed. 4. Make sure the fuel control linkage goes to full throttle and does not stick when released.

6. Install a temperature gauge with the probe in the transmission converter out (to cooler) line. Allison DOC™ displays sump temperature only. 7. Perform a Cold Check of the transmission fluid level and adjust as necessary. 8. Connect Allison DOC™ to the vehicle diagnostic data connector or install an accurate tachometer (do not rely on the vehicle tachometer). 9. Install wheel chocks. 10. A driver is in the driver’s position. 11. The vehicle’s service/park brakes are fully applied.

WARNING! To help avoid personal injury, such as burns, from hot transmission fluid and/or to help avoid equipment damage, do not stall the torque converter for more than ten seconds maximum and monitor transmission fluid temperature. Immediately return the engine to idle if converter out (to cooler) temperature exceeds 150ºC (300ºF). Operating the transmission at high engine power at transmission stall or near stall conditions causes a rapid rise in the transmission fluid temperature. The fluid in the transmission torque converter is absorbing all of the engine power and the vehicle cooling system cannot dissipate the excessive heat load. Extended operation under high heat load conditions causes transmission and cooling system damage, and can possibly fail hydraulic lines causing leaking high temperature fluid.


2–9

4000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4 th GENERATION 8. Record converter out (to cooler) temperature.

WARNING! To help avoid personal injury and equipment damage while conducting a transmission stall test, the vehicle must be positively prevented from moving. Apply the parking brake, the service brake, and chock the wheels securely. Warn personnel to keep clear of the vehicle and its travel path.

9. Reduce engine speed to idle and shift the transmission to N (Neutral). 10. Raise engine speed to 1200–1500 rpm for two minutes to cool the transmission fluid. 11. At the end of two minutes, record converter out (to cooler) temperature. d. Driving Transmission Stall Test

c. Performing a Transmission Stall Test 1. Start the engine. While in neutral let the transmission warm to normal operating temperature: — Sump temperature: 71–93ºC (160–200ºF) — Converter out temperature: 82–104ºC (180–220ºF) 2. Perform a Hot Check of the transmission fluid level and adjust as necessary. 3. Turn OFF all engine accessories. 4. Use Allison DOC™ For PC–Service Tool to select fourth range. Using fourth range reduces the torque imposed on the transmission and driveline. Do not perform a transmission stall test in Reverse.

CAUTION: To help avoid transmission or driveline damage, full throttle transmission stall tests must never be performed in reverse range (all models) or low ranges (7-speed models). 5. Notify personnel in the area to keep clear of the vehicle. 6. Slowly increase engine rpm until engine speed stabilizes. 7. Record engine speed.

CAUTION: The transmission stall test procedure causes a rapid rise in transmission fluid temperature that can damage the transmission. Never maintain a stall condition once engine speed stabilizes or converter out (to cooler) temperature exceeds 150ºC (300ºF). During a stall condition, converter out temperature rises much faster than internal (sump) temperature. Never use sump fluid temperature to determine the length of the stall condition. If the stall test is repeated, do not let the engine overheat. 2–10

NOTE: If the vehicle is equipped with a smoke controlled or an emission controlled engine or engine control programming inhibits engine acceleration, the following transmission stall test procedure can be used.

CAUTION: To help avoid personal injury and/or equipment damage, a driving transmission stall test must be performed by a trained driver and a qualified technician. e. Driving Transmission Stall Testing Preparation. If a transmission stall test is to be performed, make sure the following preparations have been made before conducting the transmission stall test. 1. The manufacturer concurs with performing a full-throttle stall test. 2. Engine programmable parameter for 0 rpm output speeds are set higher than value expected for stall speed. 3. The vehicle is in an area in which a transmission stall test can be safely performed. 4. Make sure the fuel control linkage goes to full throttle and does not stick when released. 5. Inspect the engine air induction system and exhaust system for restrictions. 6. Perform a Cold Check of the transmission fluid level and adjust as necessary. 7. Install a temperature gauge with the probe in the transmission converter out (to cooler) line. Allison DOC™ displays sump temperature only.


PREVENTIVE MAINTENANCE 8. Install an accurate tachometer (do not rely on the vehicle tachometer). 9. Connect Allison DOC™ to the vehicle diagnostic data connector. f. Performing a Driving Transmission Stall Test 1. Start the engine while in Neutral and let the transmission warm to normal operating temperature — Sump temperature: 71–93ºC (160–200ºF) — Converter out temperature: 82–104ºC (180–220ºF) 2. Perform a Hot Check of the transmission fluid level and adjust as necessary.

11. Raise engine speed to 1200–1500 rpm for two minutes to cool the transmission fluid. At the end of two minutes, record converter out (to cooler) temperature g. Neutral Cool-Down Check Procedure 1. At the end of two minutes, converter out (to cooler) fluid temperature should return to within normal operating temperature range. 2. If the transmission fluid does not cool within two minutes, the cause could be a stuck torque converter stator or an issue with the transmission cooler, lines, or fittings. h. Transmission Stall Test Results

3. Turn OFF all engine accessories. 4. While located in isolated area, begin the driving transmission stall test.

NOTE:

6. Operate the engine at 100 percent full throttle, maximum governed speed.

Environmental conditions, such as ambient temperature, altitude, engine accessory loss variations, etc., affect engine performance/power. Due to such conditions, stall speed can vary from specification by +/-150 rpm and still be accepted as within published stall speed.

7. With the engine at maximum governed speed, begin gradually applying the vehicle service brakes while maintaining 100 percent full throttle.

If engine speed with the transmission stalled is more than 150 rpm below the stall speed specified, an engine issue is indicated.

5. Select a hold range that will limit road speed (usually 2nd or 3rd range). Never perform a driving stall test in Reverse or Low range (7-speed models).

8. When the vehicle comes to a complete stop, record engine speed.

CAUTION:

If engine speed with the transmission stalled is more than 150 rpm above specification, a transmission issue is indicated.

The transmission stall test procedure causes a rapid rise in transmission fluid temperature that can damage the transmission. Never maintain a stall condition once engine speed stabilizes or converter out (to cooler) temperature exceeds 150ºC (300ºF). During a stall condition, converter out temperature rises much faster than internal (sump) temperature. Never use sump fluid temperature to determine the length of the stall condition. If the stall test is repeated, do not let the engine overheat.

Conditions that can exist to cause stall speed to be 150 rpm above specification could be:

9. Record converter out (to cooler) temperature.

A low stall speed that is at least 33 percent lower than the published stall speed could indicate an engine issue or a freewheeling stator in the torque converter.

10. Reduce engine speed to idle and shift the transmission to N (Neutral).

— Transmission fluid cavitation or aeration. Verify proper fluid level using the oil level sensor, if equipped, or dipstick. — Slipping clutch. — Torque converter malfunction. — Sticking/damaged torque converter valve


2–11

4000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4 th GENERATION 2–15. READING CLUTCH PRESSURES

C3

a. Purpose. Reading individual clutch pressures helps to determine if a transmission malfunction is due to a mechanical or an electrical problem. Properly making these pressure readings requires transmission and vehicle (or test stand) preparation, recording of data, and comparing recorded data against specifications provided.

C5

NOTE: Determine if there are diagnostic codes set that are related to the transmission difficulty you are evaluating. Proceed to make mechanical preparations for reading clutch pressures only after codes have first been evaluated. b. Transmission and Vehicle Preparation

CAUTION: Be sure that the hydraulic fittings have the same thread as the plugs removed (7⁄16-20 UNF-2A). These fittings must be straight thread, O-ring style. Failure to use properly threaded fittings will damage the control module. 1. Remove the plug from the pressure tap and install a hydraulic fitting and a pressure gauge or transducer at each location where measurement is desired (refer to Figure 2–3 or Figure 2–4). Pressure gauge set J 26417-A is available for this purpose. Refer to Table 2–5 for pressure levels expected. 2. Provide for engine speed to be monitored. (The Allison DOC™ For PC–Service Tool may be used.) 3. Be sure that transmission sump fluid temperature can be measured. (The Allison DOC™ For PC–Service Tool may be used.) 4. Be sure that the transmission has enough fluid for cold operation until an operating temperature fluid level can be set.

2–12

LU

MAIN C2 C4 C1 V07322.00.02

Figure 2–3. Clutch Pressure Check Points (Except 4700 and 4800 Models)

5. Bring the transmission to normal operating temperature of 71–93ºC (160–200ºF). Inspect for fluid leaks in the circuits being tested. Repair leaks as needed. Be sure that fluid level is correct. c. Recording Data 1. The Allison DOC™ For PC–Service Tool allows reading of individual range clutch pressures with the vehicle stationary. Clutch Test instructions are located in the Action Request section of the Allison DOC™ For PC– Service Tool User Guide, GN3433EN. Follow instructions to read clutch pressures in individual ranges. NOTE: Read lockup clutch pressure by driving the vehicle in a range where lockup can be obtained. Record the pressure values at the engine speed and sump fluid temperature values shown in Table 2–5. The lockup clutch is functioning correctly when engine speed and turbine speed values are equal as recorded from the Allison DOC™.


PREVENTIVE MAINTENANCE 2. Operate the transmission at the conditions shown in Table 2–5 and record engine speed, transmission sump fluid temperature, main pressure, and clutch pressures in the ranges where a problem is suspected. d. Comparing Recorded Data To Specifications 1. Be sure that engine speed and transmission sump fluid temperatures were within the values specified in Table 2–5.

6. Return the transmission to its original configuration. (Remove instrumentation and reinstall any components removed for the pressure testing.)

LOCKUP PRESSURE TAP

C6 PRESSURE TAP (On left side of adapter housing, near the bottom)

MAIN

C4

2. Compare the main pressure and clutch pressure data, recorded in Step B, with the specifications in Table 2–5.

C1

C5

C3 C2

MAIN

LUBE

3. If clutch pressures are within specifications, return the transmission and vehicle to their original configuration and proceed with electrical troubleshooting. 4. If clutch pressures are not within specification, take corrective action to replace the internal parts of the transmission necessary to correct the problem. 5. Reread pressure values after the transmission has been repaired.

DRAIN PLUG OIL FILTER COVERS LUBE PRESSURE TAP

CLUTCH PRESSURE TAPS V05596.01.00

Figure 2–4. 4700 and 4800 Models Clutch Pressure Check Points (4700 and 4800 Models)


2–13

2–14


580–620

4000 Product Family—Idle

Neutral Main Mod OFF Neutral Main Mod ON Reverse Main Mod OFF Reverse Main Mod ON Low C (4000 7-Speed) Main Mod OFF Low C (4000 7-Speed) Main Mod ON 1C Main Mod OFF 1C Main Mod ON 2C Main Mod OFF 2C Main Mod ON

Range

C1, C4

C1, C4

C1, C5

C1, C5

C1, C6

C1, C6

C3, C5

C3, C5

C5

C5

Clutches Applied 1515–2055 (220–300) 1310–1725 (190–250) 1450–2055 (210–300) 1170–1585 (170–230) 1240–1725 (180–250) 870–1340 (125–195) 1240–1725 (180–250) 870–1340 (125–195) 1240–1725 (180–250) 870–1340 (125–195)

Main kPa (psi) 1440–2055 (210–300) 1235–1725 (180–250) 1375–2055 (200–300) 1095–1585 (160–230) 1165–1725 (170–250) 795–1340 (115–195) 1165–1725 (170–250) 795–1340 (115–195) 1165–1725 (170–250) 795–1340 (115–195)

Range Clutch* kPa (psi) 3.5 min (0.5 min) 3.5 min (0.5 min) 3.5 min (0.5 min) 3.5 min (0.5 min) 3.5 min (0.5 min) 3.5 min (0.5 min) 3.5 min (0.5 min) 3.5 min (0.5 min) 3.5 min (0.5 min) 3.5 min (0.5 min)

Lockup Clutch* kPa (psi)

* To pass this specification, measured clutch pressures must be within 75 kPa (10 psi) of actual measured main pressure and still be within the minimum and maximum value of this specification.

Engine rpm

Transmission Model/Test Type

Pressure Specifications

Table 2–5. Main Pressure and Clutch Pressure Specifications (Sump Fluid Temperature 71–93°C; 160–200°F)



1780–1820

4000 Product Family—High Speed

C3, C5 C1, C6

Low C (4000 7-Speed) C1, C5 C1, C4 C1, C4, LU C1, C3 C1, C3, LU C1, C2 C1, C4, LU C2, C3 C2, C3, LU C2, C4 C2, C4, LU

1C 2C 2L 3C 3L 4C 4L 5C 5L 6C 6L

C5

C5

Clutches Applied

Neutral Main Mod OFF Neutral Main Mod ON Reverse

Range 1805–2055 (260–300) 1415–1725 (205–240) 1805–2055 (260–300) 1550–1795 (225–260) 1550–1795 (225–260) 1550–1795 (225–260) 1080–1365 (155–200) 1550–1795 (225–260) 1080–1365 (155–200) 1550–1795 (225–260) 1080–1365 (155–200) 1550–1795 (225–260) 1080–1365 (155–200) 1345–1590 (195–230) 1035–1235 (150–180)

Main kPa (psi) 1730–2055 (250–300) 1340–1725 (195–240) 1730–2055 (250–300) 1475–1795 (215–260) 1475–1795 (215–260) 1475–1795 (215–260) 1005–1365 (145–200) 1475–1795 (215–260) 1005–1365 (145–200) 1475–1795 (215–260) 1005–1365 (145–200) 1475–1795 (215–260) 1005–1365 (145–200) 1270–1590 (185–230) 960–1235 (140–180)

Range Clutch* kPa (psi)

160–240 (23–35) 160–240 (23–35) 160–240 (23–35) 160–240 (23–35) 160–240 (23–35) 160–240 (23–35) 160–240 (23–35) 160–240 (23–35) 160–240 (23–35) 125–200 (18–30) 125–200 (18–30) 125–200 (18–30) 125–200 (18–30) 125–200 (18–30) 125–200 (18–30)

Lockup Clutch* kPa (psi)

* To pass this specification, measured clutch pressures must be within 75 kPa (10 psi) of actual measured main pressure and still be within the minimum and maximum value of this specification.

Engine rpm

Transmission Model/Test Type

Pressure Specifications

Table 2–5. Main Pressure and Clutch Pressure Specifications (cont’d) (Sump Fluid Temperature 71–93°C; 160–200°F)

PREVENTIVE MAINTENANCE

2–15

4000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4 th GENERATION 2–16. FLUID LEAK DIAGNOSIS Most fluid leaks can be located and repaired by visually finding the leak and replacing or repairing the necessary parts. On some occasions, a fluid leak may be difficult to locate or repair. The following procedure may help in locating and repairing most leaks.

1. Pour the specified amount of dye into the transmission fill tube. 2. Operate the vehicle under normal operating conditions as directed in the kit. 3. Direct the black light toward the suspected area. The dyed fluid will appear as a brightly colored path leading to the source.

a. Finding The Leak 1. Identify the fluid. Determine whether it is engine oil, automatic transmission fluid, or hydraulic fluid from a specific vehicle system. 2. Operate the vehicle to reach normal operating temperature and park the vehicle. After a few minutes, look for dripping fluid to identify the approximate location of the leak. 3. Visually inspect around the suspected area. Inspect all gasket mating surfaces for leaks. A mirror is useful for finding leaks in areas that are hard to reach. 4. If the leak still cannot be found, clean the suspected area with a degreaser, steam, or spray solvent. Completely clean and dry the area. Operate the vehicle for several miles at normal operating temperature and varying speeds. After operating, visually inspect the suspected leak area. If the leak is not located, use the powder or black light and dye methods. b. Powder Method

d. Possible Points of Fluid Leaks and Their Causes 1. Transmission mating surfaces: • Bolts improperly tightened • Improperly installed or damaged gasket • Mounting face damaged

2. Housing: • Filler pipe seal damaged or missing • Filler pipe bracket dislocated • Oil cooler connector fittings loose or

damaged • Output shaft seals worn or damaged • Pressure port plugs loose • Porous casting

3. Converter end: • Converter seal damaged

1. Clean the suspected area.

• Seal lip cut (inspect converter hub for

2. Apply an aerosol-type white powder, such as foot powder, to the suspected area. 3. Operate the vehicle under normal operating conditions. 4. Visually inspect the suspected area and trace the leak path over the white powder surface to the source. c. Black Light and Dye Method

damage) • Garter spring missing from seal • Converter leak in weld area • Damaged or missing converter O-ring seal • Porous casting

4. Breather or fill tube: • Overfilled—incorrect dipstick

NOTE: A dye and black light kit is available for finding leaks. Refer to the manufacturer’s directions when using the kit. Refer to kit directions for the color of the fluid and dye mix.

• Plugged breather • Water or coolant in fluid—fluid will appear

milky • Incorrect electronic fluid level indication • Drain-back holes plugged

2–16


PREVENTIVE MAINTENANCE 5. Gaskets:

• Output shaft surface scratched, nicked, or

• Fluid level/pressure is too high • Plugged vent or drain-back holes • Improperly tightened fasteners or dirty/

damaged threads • Warped flanges or sealing surface • Scratches, burrs, or other damage to a

sealing surface • Damaged or worn gasket

damaged • Loose or worn bearing causing excess seal

wear e. Repairing the Leak. Once the leak has been located and traced to its source, repair the leaking components. If a gasket is replaced, but the sealing flange is bent, the new gasket will not repair the leak. The bent flange must also be repaired.

2–17. OUTPUT FLANGE/YOKE AND OIL SEAL MAINTENANCE

• Cracked or porous casting • Improper sealant used (where applicable)

6. Seals: • Fluid level/pressure is too high

a. Disassembly (Figures 2–5 and 2–6) 1. Remove one bolt 8, retainer plug 7, O-ring 6, and O-ring 5.

• Damaged seal bore

2. Remove flange 3 or yoke 4. Inspect journal sealing area. Minimum journal area diameter is 85 mm (3.346 inch).

• Damaged or worn seal

3. Inspect slinger 2. Replace if damaged.

• Improper installation

4. Remove oil seal 1 using tool J 24171-A or equivalent.

• Plugged vent or drain-back holes

• Cracks in component

3 1 2

3

4 5 6

7 8

V06834.01.00

Figure 2–5. Output Flange and Oil Seal (Except 4700 and 4800 Models)


2–17

4000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4 th GENERATION 2–18. ON-VEHICLE MAINTENANCE

b. Assembly (Figure 2–5 and 2–6) 1. Install oil seal 1 using installer J 37031-A (except 4700 and 4800 models) or J 43024 (4700 and 4800 models), and J 8092 or equivalent. 2. If removed, use special tool J 46150 to press a new slinger 2 onto the flange or yoke.

The following may be serviced or removed with the transmission mounted in the vehicle. Refer to the indicated paragraph for removal instructions:

3. Install flange 3 or yoke 4.

Item

Paragraph

4. Install O-ring 5 on plug 7.

PTO(s)

4–2b

5. Insert bolt 8 through retainer plug 7.

Oil Fill Tube

4–2c(2)

6. Install an O-ring 6 over the threaded end of bolt 8 so that the O-ring seats against the retainer plug.

Remote Cooler Manifold

4–2c(3)

Input, Turbine, and Output Speed Sensor

4–2c(7)

7. Install retainer plug 7 into the yoke or flange. Tighten bolt 8 to 70–80 N·m (51–60 lb ft).

Control Module

4–2f

3 1 2

3

4 5 6

7 8

V05578.01.00

Figure 2–6. Output Flange and Oil Seal (4700 and 4800 Models)

2–18


SECTION 3—GENERAL OVERHAUL INFORMATION 3–1.

SCOPE

• • • • • • • • • • •

This section provides general information for transmission overhaul. The information provided includes: • Tools and equipment required for overhaul • Replacement parts information • Cleanliness and careful handling • Cleaning and inspection • Assembly procedures • Transmission removal and installation • Locating wear data • Locating spring specifications • Locating torque specifications for plugs, bolts, and nuts

3–2.

• • • • •

TOOLS AND EQUIPMENT

a. Improvised Equipment. A work table—700 kg (1500 pound) capacity (Figure 3–1) may be improvised. b. Special Tools. Special tools are illustrated in Figure 3–2 and Figure 3–3 and are identified in Table 3–1 and Table 3–2. c. Mechanic’s Tools and Shop Equipment. The following tools, in addition to the common tools ordinarily required, should be available. Common hand tools, metric where required • Metric wrench set (sockets, box-end wrenches,

and Allen wrenches)

Snapring (retaining ring) pliers Micrometer (metric preferred) Depth micrometer (metric preferred) Dial indicator set (metric preferred) Metric headless guide bolts set M16 eye bolt M10 eye bolt Suitable hoist—900 kg (2000 lb) capacity A 20 N·m (150 lb inch) torque wrench A 500 N·m (350 lb ft) torque wrench Clean, lint-free shop cloths (do not use waste cloths) A press for disassembly and assembly of spring-loaded clutches and interference-fit parts Containers for parts Supply of wood blocks Petrolatum Container of mineral spirits for cleaning parts

WARNING! Use appropriate safety equipment such as safety glasses, safety shoes, and gloves.

CAUTION; Caustic cleaning compounds will damage some transmission parts. Use only mineral spirits to clean transmission parts.

120 cm (48 in.) 200 cm (78 in.)

OIL DRAIN

60 cm (24 in.) OIL DRAIN (BOTH SIDES)

10x10 cm (4x4 in. LEGS)

STEEL TOP

TROUGH 16-GAUGE SHEET STEEL 35 mm (11Ú2 in.) DEEP 35 mm (11Ú2 in.) WIDE 5x15 cm (2x6 in. BOARD) FOR TOP FRAME AND LEG BRACKETS V00660.02

Figure 3–1. Work Table


3–1


1

2

5

4

3

6 11 7

10

9

8

14

12

15

13

17

18

19

16

22

21

20

23 26 24

27

25

28

31 29

NOTE: Objects are not shown to scale

V06922.02.00

Figure 3–2. 4000 Product Family Special Tools

3–2

30


GENERAL OVERHAUL INFORMATION Table 3–1. 4000 Product Family Special Tools* Kent-Moore Figure 3–2 Tool No.** Item No. Description J 3940 1 Bearing Race Remover J 8092 2 Drive Handle J 24171-A J 26417-A J 29109 J 33163

3 29 4 5

J 33884 J 35923-2 J 35924 J 35926 J 37030-1 J 37030-2 J 37030-3 J 37031-A J 37032 J 37033 J 37034

NA 19 7 24 17 18 20 22 9 10 15

Seal Remover Pressure Gauge Set Overhaul Stand Valve Body Parts Tray Set (includes J 33163-1 and J 33163-2) Pressure Switch Test Block C1 Spring Compressor (use with J 37030-3) Main-Pressure Spring Remover/Installer Transmission Holding Bracket C2 Spring Compressor (use with J 37030-3) C5 Spring Compressor (use with J 37030-3) C1, C2, and C5 Spring Compressor Tool Base Output Seal Installer Input Seal Installer Output Bearing Cup Installer (use with J 37034) Output Bearing Installer/Drive Sleeve

J 37035

11

Spanner Nut Torque Tool Set

J 37036

12

J 37038

21

J 37040 J 37041 J 38548 J 38564 J 39534 J 39949 J 39954 J 41445 J 41462 J 42048 J 46150 J 47942

13 14 27 25 26 8 16 23 6 28 30 31

Turbine Shaft Bushing/Output Bushing/P2 Carrier Bushing Installer P1 Carrier Bushing and Ground Sleeve Bearing, Pump Body Bushing, and Bearing Retainer Bushing Installer Rotating Clutch Bushing Installer Front Support Sleeve and PTO Bearing Installer Torque Converter End Play Gauge Torque Converter Bolt Tool Wear Plate Rivet Installer Torque Converter Cover Bushing Installer Charging Pump Bushing Installer Transmission Holding Bracket Main-Pressure Relief Spring Compressor Retarder Flow Valve Spring Compressor Slinger Installer Valve Body Spring Compressor

Reference Paragraph 5–14c,e; 5–16a,c 2–17b; 5–3b; 5–5e; 5–6b,c; 5–7b; 5–10b; 5–11b; 5–14g; 5–16e 2–17a; 5–5b; 5–6a; 5–14c; 5–16a 2–15b 4–2a; 6–2a 5–18a NA 5–7a,b 5–18e,h 4–2a; 6–2a 5–7a,b 5–14e,f; 5–16c,d; 5–17c 5–7a,b; 5–14e,f; 5–15f; 5–16c,d 6–2q,s 5–5e; 5–6c 5–14f,h; 5–15g,h 5–5e; 5–6b,c; 5–14f,g,h; 5–15g,h,i,j; 5–16d,e,f; 5–17d,e,f 5–14c,h; 5–15c,j; 5–16a,f; 5–17a,f; 6–2q,r,s,t 5–7b; 5–11b; 5–14g; 5–16e 5–5e; 5–6b, c; 5–10b

5–7b 5–5d; 5–6b 5–3b; 6–2v 4–2g NA 5–3b 5–6c 4–2a; 6–2a 5–6a,b 5–14c,h; 5–15c,j 6–2z 5–18c,j

*

We believe this source and its tools to be reliable. These tools may be available from other manufacturers. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or tools from these firms, or for any such items that may be available from other sources.

**

Kent-Moore Tool Division, 29784 Little Mack, Roseville, Michigan 48066


3–3


1

2

3

4

6

5

8

7

10 9

23 11

14 24 17

16

15 25

12 19

18

20

13

21

NOTE: Objects are not shown to scale

V06923.02.00

Figure 3–3. 4700 and 4800 Model Special Tools

3–4

22


GENERAL OVERHAUL INFORMATION Table 3–2. 4700 and 4800 Model Special Tools*

Kent-Moore Tool No.** J 3940 J 8092 J 24171-A J 35923-4 J 35926-A

Figure 3–3 Item Number 1 2 3 11 13

J 35926-UPD

NA

J 37030-2 J 37030-3 J 37032 J 37033 J 37034

10 11 4 5 9

J 37035 J 37036

6 8

J 41445 J 42048 J 43020 J 43023 J 43024 -A J 43025 J 43046 J 43047 J 43202 J 43278

12 23 15 16 17 18 19 20 21 7

J 43922 J 43975

22 14

J 46150 J 47942

24 25

Description Bearing Race Remover Drive Handle Seal Remover Spring Compressor Tool Base Transmission Lifting Bracket (modified to lift 4700 and 4800 models) Modification Template (used to modify J 35926 to become J 35926-A) C5 Spring Compressor C1, C2, and C5 Spring Compressor Tool Base Input Seal Installer Output Bearing Cup Installer Output Bearing Installer/Drive Sleeve Spanner Nut Torque Tool Set Turbine Shaft Bushing/Output Bushing/P2 Carrier Bushing Installer Transmission Holding Bracket Retarder Flow Valve Spring Compressor P3 Planetary Lifting Ring P4 Planetary Bushing Installer Output Shaft Seal Installer C5 Return Spring Torque Wrench Adapter Bearing Installer/Remover Output Shaft Bearing Installer Output Shaft Holding Tool

Reference Paragraph 5–15d,f; 5–17c 2–17b; 5–15i; 5–17e 2–17a; 5–15c; 5–17a 5–13d,e; 5–17d 4–2a; 6–2a NA 5–15f,g; 5–17c 5–15f,g; 5–17c NA 5–16d; 5–17d 5–13d,e,f; 5–15g,h,i,j; 5–17d,e,f; 6–2r,t 5–15c,j; 5–17a,f; 6–2r,s,t 5–15i; 5–17e

4–2a; 6–2a 5–15c,j 4–2n; 6–2k 5–13f 2–17b; 6–2r,t 5–13d,e; 5–17d 4–2m; 6–2l 5–13d,e 5–15i; 5–17e 5–14h; 5–15j; 5–16f; 5–17a,f; 6–2r,t Measuring Blocks And Straight Edge 6–2m,n 4700 and 4800 Model Tool Kit (Includes the following NA special tools: J 43020, J 43023, J 43024, J 43025, J 43046, J 43047, J 43202, J 43278, and J 43922) Slinger Installer 6–2z Valve Body Spring Compressor 5–18c,j

*

We believe this source and its tools to be reliable. These tools may be available from other manufacturers. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or tools from these firms, or for any such items that may be available from other sources.

**

Kent-Moore Tool Division, 29784 Little Mack, Roseville, Michigan 48066


3–5


REPLACEMENT PARTS

a. Ordering Information. Refer to the current issue of 4000 Product Family Parts Catalog PC2456EN for parts information. Do not order replacement parts using the reference numbers in this service manual. b. Parts Normally Replaced at Overhaul. The following parts are normally replaced at each transmission overhaul: • Gaskets • Lockstrips • Washers or retaining rings damaged by

removal or abnormal wear • Oil seals and piston sealrings • Spiral retaining ring 4 (Foldout 8) • Suction filter 5 (Foldout 11)

CAUTION: Seal all openings and the breather before steam cleaning the transmission. The material on friction-faced clutch plates, the bonding agent, and clutch housing machined surfaces can be damaged by water, steam cleaning, or unapproved solvents and detergents. Use only mineral spirits to clean friction-faced clutch plates and clutch housings. 1. Clean all metallic transmission parts, except bearings and friction-faced clutch plates, by steam cleaning or with mineral spirits. Do not use caustic soda solution for steam cleaning. If steam cleaning, do not allow steam or water to enter the transmission. Clean friction-faced clutch plates and bearings with mineral spirits only. 2. Dry all parts, except bearing assemblies, with compressed air. To prevent rust, lubricate steam-cleaned parts as soon as they are dry.

WARNING! Do not burn discarded Teflon® seals; toxic gases are produced by burning Teflon.

3–4.

b. Cleaning Transmission, Parts

3. Clean fluid passages by working a piece of soft wire through the passages and flushing them with mineral spirits. Dry the passages with compressed air.

CAREFUL HANDLING

Handle parts and subassemblies carefully to prevent nicking, scratching, and denting. Parts that fit together closely and have a specific operating clearance can bind if damaged. Parts that depend upon smooth surfaces for sealing may leak if scratched. Control valve body assembly parts are especially susceptible to leaking if scratched (valves, when dry, must move freely by their own weight). Handle these parts carefully and protect them during removal, cleaning, inspection, and installation. Keep control valve body assembly parts in clean containers until installation.

4. Examine parts, especially fluid passages, after cleaning to make certain they are entirely clean. Re-clean parts if necessary. 5. Removal of minor defects with such items as crocus cloth, honing stones, and scrapers produces debris and residue. Cover adjacent parts, ports, and cavities before removing defects. Thoroughly reclean the affected areas after rework. c. Cleaning Bearings

WARNING!

3–5.

CLEANING AND INSPECTION

a. Dirt Causes Malfunction. All parts must be clean to permit effective inspection. Do not allow dirt or foreign material to enter the transmission during assembly. Even minute particles can cause close-fit parts, such as valves, to malfunction. 3–6

Never dry bearings by spinning them with compressed air. A spinning bearing can disintegrate, allowing balls or rollers to become lethal flying projectiles. Also, spinning a bearing without lubrication can damage the bearing. 1. Bearings that have been in service should be thoroughly cleaned in mineral spirits.


GENERAL OVERHAUL INFORMATION 2. Soak particularly dirty bearings or ones filled with hardened grease in mineral spirits before trying to clean them.

• If a bearing is not installed immediately, wrap

3. Before inspection, lubricate bearings with transmission fluid.

f. Inspecting Cast Parts and Machined Surfaces

d. Inspecting Bearings

CAUTION: If excessive metal contamination has occurred, replacement of all bearings is recommended. 1. Inspect bearings for rough rotation. Replace a bearing if its rotation is still rough after cleaning and lubrication. 2. Inspect bearings for scored, pitted, scratched, cracked, or chipped races, and for excessive roller or ball wear. Replace the bearing if any of these defects are found. 3. Inspect a defective bearing’s bore and mating shaft for grooved, burred, or galled conditions that indicate the bearing has been turning in the bore or on the shaft. If shaft or bore damage cannot be repaired with crocus cloth, replace the defective part. 4. When removing a bearing, do not apply pressure across the balls. This can cause brinelling and bearing failure.

or cover the lubricated bearing with clean paper or lint-free cloth to keep out dust.

1. Inspect bores for wear, scratches, grooves, and dirt. Remove scratches and burrs with crocus cloth. Clean the part. Replace parts that are deeply scratched or grooved. 2. Inspect all fluid passages for obstructions. If an obstruction is found, remove it with compressed air, or by working a soft wire back and forth through the passage and flushing it with mineral spirits. 3. Inspect mounting faces for nicks, burrs, scratches, and foreign matter. Remove any defects with crocus cloth or a soft stone. Clean the part. If scratches are deep, replace the defective part. 4. Inspect threaded openings for damaged threads. Chase damaged threads with a correctly sized tap. Clean the part. 5. Inspect the ribs inside the main housing for reaction plate wear grooves in the side of the ribs. Replace housings that have wear grooves beyond wear limits. (Refer to Wear Limits, Table 7–1 in Section 7.) 6. Replace housings or other cast parts that are cracked.

5. If a bearing must be removed or installed without the proper tool, press only on the race which is adjacent to the mounting surface.

7. Inspect all machined surfaces for damage that could cause fluid leakage or other malfunction. Rework or replace defective parts.

e. Keeping Bearings Clean. Ball or roller bearing failures are usually caused by dirt or grit in the bearing. Keep bearings clean during removal and installation. Observe the following rules to be sure maximum bearing life:

8. Inspect the oil tracks of the control module and main housing for porosity, broken lands, cracks, dirt, and land surface imperfections. These imperfections will cause severe fluid leakage leading to transmission failure.

• Do not unwrap new bearings until they are to

be installed. • Do not remove the grease in which new

bearings are packed until they are to be installed. • Do not lay bearings on a dirty bench. Place

bearings on clean paper, or lint-free cloth.

g. Inspecting Bushings and Thrust Washers 1. Inspect bushings for scores, burrs, sharp edges, and evidence of overheating. Remove scores with crocus cloth. Remove burrs and sharp edges with a scraper or knife blade. Before reinstalling, carefully check bushings for signs of distress. Clean the part.


3–7

4000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4 th GENERATION i. Inspecting Gears

CAUTION: When removing a defective bushing, do not damage the bushing bore. 2. Replace bushings that are out-of-round, deeply scored, or excessively worn. Inspect parts mated to bushings to be sure they are not damaged or worn beyond use. 3. Inspect thrust washers for distortion, scores, burrs, and wear. Replace a thrust washer if defective or worn. h. Inspecting Sealrings and Gaskets 1. Inspect piston sealrings and lip-type seals for nicks, cuts, tears, splits, and pattern damage. A damaged seal can indicate rough or sharp edges in piston grooves or on a mating surface that could damage a new seal. 2. Inspect piston sealring grooves for nicks, burrs, dents, or displaced metal that could damage the new seal. Remove raised metal, sharp edges, burrs, or nicks with a soft stone and crocus cloth. Thoroughly clean all residue from the piston before assembly. 3. Replace all composition gaskets. 4. Inspect hook-type sealrings for wear, broken hooks, and distortion. Install a new hook-type sealring if the old ring shows any wear on its outside diameter, or if there is excessive side wear. Install a new sealring if there is wear on the sealring outside diameter mating surface. 5. Inspect clutch housing sealing surfaces for nicks, burrs, dents, or displaced metal that could interfere with mating parts or damage the piston seal. Remove raised metal, sharp edges, burrs, or nicks with a soft stone and crocus cloth. Thoroughly clean all residue from the housing before assembly. 6. Measure butt-joint sealring end gap by inserting the sealring into its respective sealing bore. Use a feeler gauge to measure end gap. Discard sealrings that do not meet specifications. Refer to Table 7–1, Wear Limits Data, in Section 7.

3–8

1. Inspect gears for scuffed, nicked, burred, or broken teeth. If a defect cannot be removed with a soft stone, replace the gear. 2. Inspect gear teeth for wear that has changed the original tooth shape. If this condition is found, replace the gear. 3. Inspect the thrust face of gears for scores, scratches, and burrs. Remove such defects with a soft stone. If scratches and scores cannot be removed with a soft stone, replace the gear. Thoroughly remove all residue from surface. 4. Inspect gears for load pattern and signs of distress. Any sign of distress indicates that a gear failure during operation is possible. Reusing distressed gears is an individual customer decision based upon experience. Backlash cannot be used to establish critical gear wear. Backlash tolerances are of such nature that a gear usually pits, scuffs, scores, or galls long before gear wear becomes critical. j. Inspecting Splined Parts 1. Inspect splined parts for stripped, twisted, chipped, or burred splines. Remove burrs with a soft stone. Replace the part if other defects are found. Spline wear is not considered harmful except where it affects the fit of the splined parts. Thoroughly remove all residue from surface. 2. Spline wear is determined by measuring and comparing the unworn and worn areas of the spline. This can also be checked by comparing feeler gauge thickness to the depth of the worn area. Replace parts having excessive spline wear. Refer to Table 7–1, Wear Limits Data, in Section 7. 3. Backlash cannot be used to establish critical spline wear. Accurate backlash measurement requires the mating parts to be concentrically located. k. Inspecting Threaded Parts. Inspect threaded parts for burred or damaged threads. Remove burrs with a soft stone or fine file. Replace damaged parts. Thoroughly remove all residue from surface.


GENERAL OVERHAUL INFORMATION l. Inspecting Retaining Rings. Inspect all retaining rings for nicks, distortion, or excessive wear. Replace the retaining ring if any of these defects are found. The retaining ring must snap tightly into its groove to function properly. m. Inspecting Springs. Inspect springs for signs of cracking, overheating, permanent set, or wear due to rubbing adjacent parts. Replace the spring if any of these defects are found. Refer to Table 7–2, Spring Data, in Section 7. n. Inspecting Clutch Plates (Figure 3–4) 1. Inspect friction-faced clutch plates for burrs, embedded metal particles, severely pitted faces, loose faces, excessive wear, cone, cracks, distortion, shallow oil groove depth, or damaged spline teeth. Remove burrs using a soft stone. Replace plates which have any defects. Remove all residue from part. 2. Inspect steel plates for burrs, scoring, excessive wear, excessive cone, distortion, embedded metal, galling, cracks, breaks, or damaged tangs. Remove burrs and minor surface irregularities using a soft stone. Replace plates which have any non-repairable defects. Remove all residue from part. 3. The amount of clutch plate cone is determined by measuring the distance between the inside diameter of the plate and a level surface (Figure 3–4). Discard plates having excessive cone. Refer to Table 7–1, Wear Limits Data, in Section 7. 4. Determine oil groove depth with a depth micrometer or by measuring the smooth surface (total) thickness of the plate, measuring the thickness of the steel part of the plate at the oil groove, and subtracting this measurement from the total thickness. Replace plates not having the minimum oil groove depth. Refer to Table 7–1, Wear Limits Data, in Section 7.

LEVEL SURFACE

o. Inspecting Swaged And Interference-Fit Parts. If there is evidence of looseness, replace the assembly. p. Inspecting Sealing Surfaces 1. Inspect surfaces in contact with hook-type and butt-joint sealrings for step wear, nicks, scratches, and scoring. Use a soft stone or crocus cloth to remove only the raised metal portion of these defects. Polishing the area to remove a defect is neither necessary nor desirable. If the defects are too severe to correct, replace the defective part. Remove all residue from part. 2. Inspect surfaces in contact with spring-loaded, lip-type oil seals for nicks, scratches, roughness, or other surface irregularities. Inspect for embedded particles, step wear, and dirt on flanges or other components exposed to external contamination. Remove the defects and restore the finish. Replace the part if scores or scratches permit fluid leakage. Remove all residue from part.

3–6.

ASSEMBLY PROCEDURES

a. Parts Lubrication. During final assembly, lubricate all moving parts with transmission fluid. The fluid will help protect friction surfaces and ferrous metals until the unit is in service. b. Grease Used for Assembly. During assembly use oil-soluble grease with a low melting point (petrolatum) to temporarily retain parts, butt-joint sealrings, scarf-cut sealrings, and hook-type sealrings. c. Sealing Compounds and Nonsoluble Greases. Do not use gasket-type sealing compounds, fibrous greases, or nonsoluble vegetable-base cooking compounds inside the transmission or where they could be flushed into the transmission hydraulic system. d. Clutches and Pistons 1. Soak each friction-faced clutch plate (twominute minimum) in transmission fluid before final assembly.

CLUTCH PLATE

2. Apply a generous amount of transmission fluid to the piston cavity before final assembly.

MEASURE HERE FOR CONE V00493.01

Figure 3–4. Method Of Measuring Clutch Plate Cone

3. Assemble clutch plates so that the cone of each plate faces the same direction.


3–9

4000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4 th GENERATION e. Threaded Plugs and Hydraulic Fittings

h. Butt-Joint Sealrings

CAUTION:

CAUTION: Teflon®

• Do not use tape on threaded parts where slivers can enter the transmission and cause a malfunction. • Improperly installed plugs or fittings can cause leakage and cracked housings. Threaded plugs in 4000 Product Family transmissions are the straight-thread, O-ring type. Be sure that the O-ring is in like-new condition and tighten all plugs to the torque value specified in the assembly procedure or in the exploded views. f. Coated Threaded Fasteners. Control module bolts are manufactured with a band of sealant on the threads. Coated bolts may be reused, however repeated removal and installation may reduce the effectiveness of the coating. If fluid leaks are detected around the bolts, replace the coated bolts. Do not attempt to re-apply a sealing compound. The coated bolts sizes are M10 x 1.5 x 55 mm and M10 x 1.5 x 100 mm. g. Lip-Type Oil Seals 1. When replacing lip-type seals, make sure the spring-loaded lip is toward the fluid to be sealed (toward the inside of the unit). Coat the inside of the seal with high temperature grease (MIL-G-3545A or equivalent) to protect the seal during shaft installation and to provide lubrication during initial operation. 2. The circumference of some seals is precoated with a dry sealant. The sealant is usually colored for easy identification. Precoated seals do not require any additional sealant before installation.

If humidity is allowed to penetrate and expand a butt-joint sealring, the sealring can be damaged during installation. A damaged sealring will permit transmission fluid to leak from the clutch piston cavity and cause clutch slippage. Do not open the sealed package until you are ready to install the sealring. 1. Butt-joint sealrings require special handling during assembly. The sealrings contain materials that absorb moisture from the atmosphere causing the sealring to expand. Check sealring end clearance before installation to make sure the sealring has not expanded. 2. Remove the sealring from its package and place the sealring in its operational position inside the bore that it will be sealing. 3. Use a feeler gauge to check the end clearance of the sealring. The end clearance must not be less than the specifications. Refer to the respective rebuild Steps in Section 5. 4. If the end clearance is less than specifications, bake the sealring in an oven at 93–149°C (200–300°F) for 24 hours or get a new sealring. Repeat Steps (2) and (3). 5. Pack the sealring and its groove with a liberal amount of oil-soluble grease. 6. Roll the sealring to about half its free diameter and hold it for about 10 seconds. Being careful not to spread the sealring more than necessary, slide it onto the hub. Place one end of the sealring into the groove and gradually work the seal into the groove. i. Bearings

3. Before installation, apply a non-hardening sealant to the circumference of seals not precoated with a dry sealant.

3–10

1. When removing a bearing, do not apply pressure across the balls. This can cause brinelling and bearing failure.


GENERAL OVERHAUL INFORMATION 2. If a bearing must be removed or installed without an installation sleeve, drive or press only on the race which is adjacent to the mounting surface. If a press is not available, carefully seat the bearing with a drift and a hammer, driving against the supported race. j. Bushings. Whenever a new bushing is being installed, NEVER allow the pressing tool to bottom against a needle thrust bearing. ALWAYS make sure that the pressing tool bottoms against the part that the bushing is being pressed into. k. Electrical Components. For inspection and repair of electrical components, refer to the 3000 and 4000 Product Families Troubleshooting Manual TS3989EN.

3–7.

REMOVING TRANSMISSION FROM VEHICLE (Figure 3–5)

NOTE A significant amount of fluid may drain from a hydraulic hose when it is disconnected from the transmission. 4. Disconnect all hydraulic hoses from the transmission. If a retarder is installed, disconnect the accumulator line from the retarder housing. Remove the hoses from the vehicle if they interfere with the transmission removal. Plug all openings to keep dirt from entering the hydraulic system. 5. If an integral cooler is used, drain coolant from the cooler and disconnect coolant hoses. Remove the hoses from the vehicle if they interfere with transmission removal. Plug all openings to keep dirt from entering the cooling system. b. Disconnecting Controls

a. Drain Fluid

WARNING! Avoid contact with the hot fluid or the hot sump when draining transmission fluid. Direct contact with the hot fluid or the hot sump may result in bodily injury. 1. Drain the transmission fluid before removing the transmission from the vehicle. The transmission fluid should be warm to promote complete drainage. 2. Remove the drain plug from the control module. Examine the drained fluid for evidence of contamination (see Paragraph 2–11). Reinstall the drain plug. If the drain plug threads are damaged, see Paragraph 2–12 for corrective action. 3. Remove transmission fill tube if it interferes with transmission removal.

1. Disconnect or completely remove controls. If controls are not removed from the transmission, position them so that they do not interfere with transmission removal. 2. Loosen bolt in 20-way feedthrough harness connector.

transmission

3. Disconnect the transmission external harness from the 20-way transmission feedthrough harness connector. Also disconnect the external harness from the engine, output, and turbine speed sensors (Figure 3–5). Place a cover on the transmission electrical connector to keep out dirt. Also be sure to disconnect the transmission feedthrough harness from the harness bracket. 4. If PTO(s) are used, disconnect the PTO(s) harness. 5. Disconnect the transmission external harness from the retarder temperature sensor and the retarder control valve body. c. Uncoupling Transmission From Vehicle and Engine Driveline

WARNING! DO NOT disconnect the hydraulic fluid line between the accumulator and the retarder until air and hydraulic pressure have been bled from the line.

1. Disconnect the vehicle drive shaft from the transmission output flange or yoke. Position the disconnected shaft to avoid interference with removing the transmission.


3–11


OUTPUT SPEED SENSOR

REAR COOLER PORTS

FRONT COOLER PORTS (OPTIONAL)

FRONT

REAR (WITHOUT RETARDER) PTO CONTROLS AND LINES

OUTPUT SPEED SENSOR RETARDER TEMPERATURE SENSOR

ACCUMULATOR LINE (RETARDER ONLY)

TURBINE SPEED SENSOR

REAR COOLER PORTS RETARDER “K” SOLENOID CONNECTOR

REAR (WITH RETARDER)

ENGINE SPEED SENSOR

RIGHT SIDE

V07323.01.00

Figure 3–5. Disconnection Locations

2. Transmissions with PTOs require uncoupling one of the following: • PTO from transmission • PTO drive shaft from the PTO

3. If the transmission supports the rear of the engine, place a jack or other support under the engine. 4. Securely support the transmission with a hoist, jack, or other suitable removal equipment.

3–8.

WEAR LIMITS

Refer to Table 7–1, Wear Limits Data, in Section 7, for information covering part fits, clearances, and wear limits.

3–9.

SPRING SPECIFICATIONS

Refer to Table 7–2, Spring Data, in Section 7, for spring identification and specifications.

5. Remove all bolts, nuts, washers, spacers, and supports that attach the transmission to the vehicle and the engine.

3–10.

d. Removing the Transmission 1. Move the transmission away from the engine approximately 106 mm (4.17 inch) until it is completely clear of the engine. Remove the adapter ring and/or gasket (if used). 2. Raise or lower the transmission as necessary to remove it from the vehicle.

3–12

TORQUE SPECIFICATIONS

Assembly procedures in Sections 5 and 6 specify the torque requirements for all plugs, bolts, and nuts. Torque values are also presented with the foldout illustrations in the back of this manual. Torque values specified are for dry assembly, except when otherwise noted. Wash and dry bolts and washers before assembly.


SECTION 4—TRANSMISSION DISASSEMBLY 4–1.

SCOPE

a. Mounting Transmission on Repair Stand

a. Section. This section covers disassembly of 4000 Product Family transmissions. The disassembly sequence is continuous and includes all models. b. Procedures. When a procedure does not apply to your specific model, go to the next applicable procedure. c. Illustrations. Illustrations will not always show your model, but when an operation is identical for all models, the correct procedure is shown. d. General Information. Refer to Sections 3 and 7 for general information as follows: Paragraph 3–2 3–3 3–4 3–5 3–7 7–1 7–2

Title Tools and Equipment Replacement Parts Careful Handling Cleaning and Inspection Removing Transmission From Vehicle Wear Limits Data Spring Data

1. Mount holding bracket J 35926 or J 35926-A (4700 and 4800 models), with holding bracket J 41445 attached, onto the main housing module. 2. Attach a hoist, making sure lifting attachments are placed so that the transmission is balanced, and raise the transmission to the mounting face of the overhaul stand. 3. Secure the transmission holding fixture to overhaul stand J 29109. b. Removal of Power Takeoff (Figure 4–1) NOTE: Each PTO has eight mounting bolts, two studs, and a gasket. Removal instructions are for a transmission with a single left-side or top mounted PTO. If your transmission has more than one PTO or the PTO is mounted in a different location, use the same procedure to remove the PTO(s).

e. Foldouts. Refer to Foldouts 4 through 12 for exploded views.

1. Remove eight PTO mounting bolts 1. Carefully remove PTO assembly 2, and gasket 3.

4–2.

2. Inspect two PTO studs 4 for damage and remove if necessary.

DISASSEMBLY OF TRANSMISSION

c. Removal of External Parts (Figures 4–2 and 4–3)

WARNING! PREVENT PERSONAL INJURY Use proper tools and lifting equipment when installing or removing a transmission from the repair stand. Transmission dry weights are as follows: 4000 Product Family (except 4700 and 4800 models) • Base Transmission — 377 kg (831 lb) • With PTO Provision — 405 kg (893 lb) • With Retarder — 411 kg (906 lb) • With PTO and Retarder — 439 kg (968 lb) 4000 Product Family (4700 and 4800 models) • Base Transmission — 493 kg (1087 lb) • With PTO Provision — 521 kg (1149 lb) • With Retarder — 527 kg (1162 lb) • With PTO and Retarder — 555 kg (1224 lb)

1. Inspect transmission breather 20 for damage or an obstruction. Remove if necessary for replacement or cleaning. NOTE: If your transmission is PTO equipped and you have not removed the PTO(s), return to Paragraph 4–2b. 2. Remove screw 5 retaining oil fill tube bracket 6 to the main housing module. Remove bracket 6, fill tube 8, seal 9, and dipstick 7. 3. Remove six bolts 12 retaining remote cooler manifold 11 to the main housing module. Remove remote cooler manifold 11 and gasket 10.


4–1


1

2 4 3

3

1 2

4 V06836

Figure 4–1. PTO Removal

20

ENGINE SPEED SENSOR

2 TURBINE 1 SPEED SENSOR

3

4

7 5

6

8

9 OUTPUT SPEED SENSOR

15

13 16 10 11

17

18

19

12 14

V06837.03.00

Figure 4–2. Removal of Externally Mounted Parts

4–2


TRANSMISSION DISASSEMBLY 7. Remove bolt 4, retainer 3, speed sensor 2, and O-ring 1 from the converter housing module (engine speed sensor), main housing module (turbine speed sensor), and rear cover or retarder (output speed sensor). Refer to Figure 4–3 for sensor locations. d. Removal of Integral Oil Cooler (Figure 4–4) 1. Remove two bolts 11 and seventeen bolts 12. Remove cover 13, gasket 14, and two O-rings 10. 2. Remove plate assembly 9 and four O-rings 8.

ENGINE SPEED SENSOR

OUTPUT SPEED SENSOR

TURBINE SPEED SENSOR

3. Remove nine bolts 7 and nine washers 6. Remove cooler housing 3 and gasket 1. e. Removing Integral Retarder Sump Oil Cooler (Foldout 12,C)

V09786.00.00

1. If used and not already removed, remove the retarder accumulator hose from the fitting on cooler manifold 16.

Figure 4–3. Speed Sensors

4. Remove bolt 19.

2. If not already removed, remove inlet and outlet water hoses from hose adapter 2 on the cooler manifold 16.

5. Remove flange 15 or yoke 14. Remove O-ring 17, retainer plug 18, and O-ring 16. 6. Inspect journal sealing area for minimum allowed diameter of 85.0 mm (3.346 inch).

3. Remove six bolts 5.

4

5

3 1 11 4 5

8 2 6 7 8 19 18 17 19 18 17

11

15

9 10

10

16

11 12 14 13

11

V06843

Figure 4–4. Integral Oil Cooler


4–3

4000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4 th GENERATION WARNING! To help avoid personal injury, securely support the cooler before removing the bolts retaining the cooler to the manifold. The cooler weighs 30 kg (64 lbs); use care when handling the cooler. 4. Support cooler 7 to prevent it from falling from manifold 16. 5. Remove sixteen M10 x 1.5 x 60 bolts 1. 6. Remove inlet and outlet water hose adapters 2 from cooler manifold 16. Remove two gaskets 3.

2

7. Remove cooler assembly 7. 8. Remove two gaskets 6 from the cooler. 9. Rotate the transmission so that the retarder is facing up. 10. Remove seven M10 x 1.5 x 187.5 bolts 9.

1

11. Remove M10 x 1.5 x 50 bolt 8. 12. Remove three M12 x 1.75 x 195 bolts 10. 13. Remove cooler manifold 16.

3

f. Removal of Control Valve Module (Figure 4–5)

WARNING! Get help when lifting the control module. Assistance from a hoist or another person may be required. The control module weighs approximately 25 kg (55 lb). 1. Remove forty-three bolts 3 and 4 retaining control module 1 to the main housing module, including the bolts retaining the filter covers. 2. Loosen control module 1 by applying pressure at the reinforced tabs or use jack bolts, inserted into the control module bolt holes that bottom against the main housing module. 3. Remove covers and filters if a handhold is needed to remove the control module. 4. Remove control module assembly 1 and gasket 2. 4–4

4 V09785.00.00

14. Remove gasket 4.

Figure 4–5. Control Module Removal

g. Removal of Torque Converter Module (Figure 4–6) 1. Remove any brackets installed to prevent torque converter movement. 2. Keep the torque converter cover from turning by using a heel bar, two bolts, and a screwdriver (Figure 4–6, View C). 3. Remove threaded plug 2 and O-ring 1 using a 3⁄4 inch Allen wrench (Figure 4–6, View A). 4. Attempting to loosen bolt 3 may cause the turbine and turbine shaft to rotate. Hold the turbine and turbine shaft stationary by using one of the methods listed below: • If the control module is removed, insert a

screwdriver into the vanes on the rotating clutch module (Figure 4–6, View B). • If the control module is in place, apply the

lockup clutch by applying restricted air pressure through the lockup pressure tap


TRANSMISSION DISASSEMBLY located on the main housing (Figure 4–6, View D). Insert a heel bar into a torque converter housing bolt hole. Insert two bolts into the flexplate adapter bolt holes. Then place a screwdriver at an angle to prevent converter rotation (Figure 4–6, View C). 5. Using converter bolt tool J 38564, remove bolt 3. 6. Remove selective shim 4 located under bolt 3 (Figure 4–6, View A).

CUPPED END DOWN

2

5 1

3

7. Attach a sling to the flexplate adapter by positioning the adapter connections an equal distance from each other. Using a chain hoist, carefully lift torque converter module 5 out of the converter housing (Figure 4–6, View A). 8. Place two wooden blocks on the workbench, spaced to support the torque converter module and high enough for the converter hub to clear the workbench. Lower the converter module, converter hub down, onto the blocks.

RESTRICT MOVEMENT USE HOIST AND SLING

4

J 38564

VIEW A

VIEW B

LOCKUP PRESSURE TAP

VIEW C

VIEW D

VL06840.01.00

Figure 4–6. Torque Converter Module Removal


4–5

4000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4 th GENERATION h. Removal of Converter Housing Module (Figure 4–7)

NOTE: Proceed to Paragraph 4–2 sub-paragraph shown below by output module configuration and model.

NOTE: Seven converter housing retaining bolts 3 are removed from inside converter housing 1. Use mechanical fingers or a similar tool to remove these bolts.

• i—Retarder (except 4700 and 4800 models) • j—Retarder (4700 and 4800 models) • k—Rear Cover (except 4700 and 4800 models)

1. Remove twenty-five bolts 3 that retain converter housing 1 to main housing module 4.

• l—Rear Cover (4700 and 4800 models)

2. Using the same sling used for removing the converter module, lift straight up on converter housing module 1 to remove it.

i. Removal of Retarder Module (Except 4700 and 4800 Models) (Figure 4–8)

3. Remove main housing gasket 2 from converter housing 1 or from main housing module 4.

1. Remove twelve bolts 2, three bolts 3, two bolts 4, four bolts 5, and four bolts 6 that secure retarder module 1 to main housing module 8. If used, remove the rear support bracket.

WARNING! Get help when lifting the retarder module. Assistance from a hoist or another person may be required. The retarder module weighs approximately 34 kg (75 lb).

1 3

2

2. Thread an M14 eye bolt into the retarder output shaft and lift retarder module 1 from main housing module 8.

4

3. Remove retarder gasket 7 from main housing module 8 or from retarder module 1.

V07335

Figure 4–7. Converter Housing Module Removal

2

2

2 2

2

2

2

2

1 2

2

2

4

8 7

4 6

3 6 5

2 5

5

5

2

5 3

4

6

6

6

3

OR

3 V06844

Figure 4–8. Removal of Retarder Module (Except 4700 and 4800 Models)

4–6


TRANSMISSION DISASSEMBLY 1

4

4 2

4 4

4 3

4

4

4

4

4

4

5 7

4 7 9

8

8

8

6

6 9

9

4

8

9

9

6

OR

6

7 8 V06845

Figure 4–9. Removal of Retarder Module (4700 and 4800 Models)

j. Removal of Retarder and Output Shaft Module (4700 and 4800 Models) (Figure 4–9) 1. Remove twelve bolts 4, three bolts 6, two bolts 7, four bolts 8, and four bolts 9 that secure retarder module 5 to main housing module 1. If used, remove the rear support bracket.

2. If used, remove the rear support bracket. 3. Thread an M10 or M14 eye bolt into the output shaft and lift upward to remove rear cover module 3. 4. Remove rear cover gasket 2 from main housing module 1 or from rear cover module 3.

WARNING! Get help when lifting the retarder module. Assistance from a hoist or another person may be required. The retarder module weighs approximately 34 kg (75 lb). 2. Thread an M14 eye bolt into the retarder output shaft and lift retarder module 5 from main housing module 1. 3. Remove retarder gasket 3 from main housing module 1 or from retarder module 5.

1 2

k. Removal of Rear Cover Module (Except 4700 and 4800 Models) (Figure 4–10) 1. Remove nineteen bolts 5 and washer 4, if present.

4

5

3

V06846

Figure 4–10. Rear Cover Module Removal


4–7

4000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4 th GENERATION l. Removal of Rear Cover and Output Shaft Module (4700 and 4800 Models) (Figure 4–11 and Figure 4–12) 1. Remove fourteen bolts 4 (Figure 4–12). Remove five bolts 5. 2. If used, remove the rear support bracket. 3. Thread an M14 eye bolt into output shaft 7 (Figure 4–11) and lift upward to remove rear cover module 6. 4. Remove rear cover gasket 3 from C6 adapter housing module 2 or from rear cover module 6.

m. Removal of C6 Adapter Housing Module (4700 and 4800 Models) (Figure 4–13) 1. Remove fourteen bolts 3 that secure the C6 adapter housing module 4 to main housing module 1 using special tool J 43046.

WARNING! Get help when lifting the C6 adapter housing module. Assistance from a hoist or another person may be required. The C6 adapter housing module weighs approximately 68 kg (150 lb).

1 2 4

3

6

2. Attach a sling to the C6 adapter housing module 4 with the legs of the sling equally spaced on the module. Using a chain hoist, carefully lift the C6 adapter housing module 4 from the transmission.

7

3. Remove and discard C6 adapter housing gasket 2.

5

4. Remove and discard eleven tolerance rings 5.

V05580

Figure 4–11. Removal of Rear Cover and Output Shaft Module

J 43046

2

BOLT, M12 x 1.75 x 45 (14) MARKED 4

4

3

4

4

4

4

4

4

4

4 4

4

4 BOLT, METRIC HEAVY (5) MARKED 5

1

4 4

5

5 5

5

4

5

5 V05374

V07494

Figure 4–12. Rear Cover and Output Shaft Module Bolts

4–8

Figure 4–13. Removal of C6 Adapter Housing Module (4700 and 4800 Models)


TRANSMISSION DISASSEMBLY n. Removal of P3 Planetary Module (4700 and 4800 Models) (Figure 4–14)

p. Removal of P2 Module, C5 Clutch Plates, and P1 Module (Figures 4–16 and 4–17) 1. Lift P2 planetary module 1 from the main housing module (Figure 4–17).

1. Remove selective shim 5. 2. Remove shim locating ring 4. 3. Remove P4 shaft flange 3. 4. Attach special tool J 43020 to P3 planetary 2. Attach chain hoist and lift from transmission. o. Removal of Main Shaft Module (Figure 4–15). Remove main shaft module assembly 1 from the transmission.

2. Lift C5 clutch pack from the main housing module—eight friction plates 3 and nine steel reaction plates 2 (Figure 4–16). 3. Measure the thickness and cone of each friction plate 3. Minimum thickness is 3.48 mm (0.137 inch). Maximum allowable cone is 0.25 mm (0.010 inch). 4. Measure thickness and cone of each steel reaction plate 2. Minimum thickness is 2.41 mm (0.095 inch). Maximum allowable cone is 0.25 mm (0.010 inch).

1

5. Lift P1 planetary module 1 from the transmission (Figure 4–17).

2 3

4 5 1

J 43020

C5

2 3

V05375

Figure 4–14. Removal of P3 Planetary Module E02516.01

Figure 4–16. P2 Module and C5 Clutch Plates

WIDE RATIO MODELS

1

1

1 CLOSE RATIO MODELS

2

3 V01737.00.06

E01271.01

Figure 4–15. Removal of Main Shaft Module

Figure 4–17. P1 Module


4–9

4000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4 th GENERATION q. Removal of Front Support/Charging Pump Module and Rotating Clutch Module (Figures 4–18 and 4–19) 1. Remove seven bolts 1 and seven bolts 2 that retain front support and charging pump module 3 to the main housing module (Figure 4–18). 2. Lift front support and charging pump module 3 over the turbine shaft and away from the main housing module.

CAUTION: • Always remove the turbine speed sensor before removing the rotating clutch module to avoid possible damage to the turbine speed sensor. • When you remove rotating clutch module 1, carefully place it on the workbench and prevent it from rolling off the bench. 3. Using a hoist and an M16 eye bolt, lift turbine shaft and rotating clutch module 1 (Figure 4–19) from the main housing module and place it on the workbench.

2 3

r. Removal of C3/C4 Clutch Assembly From Main Housing Module (Figure 4–20)

CAUTION: Make sure the main housing module is horizontal when removing the C3/C4 clutch assembly. 1

1. Remove fourteen bolts 3 retaining C3/C4 clutch assembly 1 in main housing module 2. 2. Remove the C3/C4 clutch assembly by sliding it out of the input end of the main housing.

V01272

Figure 4–18. Removal of Front Support/Charging Pump Module

3. Remove the main housing from the repair stand for cleaning. 4. Inspect the main housing C5 clutch plate splines. Maximum wear allowed is 1.15 mm (0.045 inch).

1 3

1

E01273.01

Figure 4–19. Removal of Rotating Clutch Module

4–10

2

E01274.01

Figure 4–20. Removal of C3/C4 Clutch Module


SECTION 5—MODULE REBUILD 5–1.

SCOPE

7. Remove turbine hub assembly 17 from torque converter cover assembly 6.

a. Section. This section describes the disassembly and assembly of the modules removed in Section 4. b. Procedures. During rebuild procedures, refer to the exploded views (Foldouts 4 through 12) in the back of this manual.

5–2.

GENERAL INFORMATION FOR MODULE REBUILD

Refer to Sections 3 and 7 for general overhaul information as follows: Paragraph 3–2 3–3 3–4 3–5 3–6 7–1 7–2

Description Tools, Equipment Replacement Parts Careful Handling Cleaning and Inspection Assembly Procedures Wear Limits Data Spring Data

8. Remove stator assembly 20. 9. If replacement is necessary, remove thrust bearing race 32 from torque converter pump assembly 33. 10. Remove thrust bearing assembly 18 from the turbine. Remove turbine hub sealring 16. Place turbine hub sealring 16 into its mating bore. Measure the ID of the sealring at the maximum distance from the hook. Replace the sealring if the maximum ID of 61.77 mm (2.432 inch) is exceeded. Inspect and measure the OD of the turbine hub 17. Minimum OD wear is 66.69 mm (2.626 inch). 11. Remove pump thrust bearing assembly 30, race 29, and selective shim 28. 12. Remove retaining ring 21. 13. Remove star plate 19. 14. Remove stator thrust plate assembly 22 and measure its thickness. Minimum thickness allowed is 9.45 mm (0.372 inch). 15. Remove stator thrust washer 23.

5–3.

TORQUE CONVERTER MODULE

a. Disassembly (Foldout 4,B) 1. Before disassembling the torque converter, note balance marks or mark a line across the converter cover to the pump assembly with a scribe. Aligning these marks will make sure the torque converter is correctly assembled and reduce balance problems. 2. Place torque converter module 4 on a flat surface—pump drive tangs downward. 3. Remove thirty-six nuts 5 from the OD of torque converter cover 7. 4. If replacement is necessary, remove damaged T-head bolt(s) 34 from the OD of torque converter pump assembly 33. 5. Carefully remove torque converter cover assembly 6 from pump assembly 33. Avoid damage to their sealing surfaces. 6. Remove O-ring 31 used between the cover assembly and pump assembly.

16. Remove and inspect stator race 24, thirteen springs 25, and rollers 26. 17. From torque converter cover assembly 6, remove forty-four bolts 14 retaining lockup clutch backplate 13 to torque converter cover assembly 7. 18. Remove lockup clutch backplate 13. Measure the thickness of the backplate wear surface. Minimum thickness allowed is 11.79 mm (0.464 inch). Measure for distortion of the lockup clutch backplate. Maximum distortion allowed is 0.15 mm (0.006 inch). 19. Remove lockup clutch damper assembly 12 from torque converter cover assembly 6. Measure the thickness of the lockup clutch. Minimum thickness allowed is 8.51 mm (0.335 inch). Measure for distortion of the lockup clutch. Maximum allowable distortion is 0.51 mm (0.020 inch). Measure spline wear between the turbine hub and the lockup clutch damper. Maximum allowable wear is 0.38 mm (0.015 inch) on either spline.


5–1

4000 PRODUCT FAMILY SERVICE MANUAL 20. Remove lockup clutch piston assembly 10. Remove inner sealring 9 and outer sealring 11 from the lockup piston assembly. Measure the thickness of the lockup piston assembly. Minimum thickness allowed is 6.53 mm (0.257 inch).

SPRING (End of spring may be up or down)

Roller to be installed in small end of cam pocket STATOR CAM

21. Inspect the ID of cover bushing 8. Maximum ID of the bushing allowed is 66.91 mm (2.634 inch). Remove the bushing if replacement is necessary. 22. Inspect converter pump hub 33. Minimum OD is 88.99 mm (3.504 inch). 23. Remove thrust bearing assembly 15. b. Assembly (Foldout 4,B and Figure 5–1) 1. Install stator race 24 into stator and cam assembly 27. 2. Install thirteen springs 25 and stator rollers 26 into stator and cam assembly 27. Be sure springs and rollers are installed as shown in Figure 5–1. Use oil-soluble grease to help hold the springs and rollers in place. 3. Install thrust washer 23 and thrust plate assembly 22 onto stator and cam assembly 27. Install star plate 19. 4. Install retaining ring 21. 5. Do not install selective shim 28 at this time. Install thrust bearing race 29 and bearing assembly 30.

Figure 5–1. Stator Roller/Spring Installation

9. Install thrust bearing assembly 15 in converter cover 7. 10. Install lockup piston sealring 9 on the hub of converter cover 7 and lockup piston sealring 11 on the OD of lockup piston assembly 10. Install the lockup clutch piston. 11. Install lockup clutch damper assembly 12 into cover 7. 12. Install lockup clutch backplate 13. 13. Install forty-four bolts 14. Tighten the bolts to 24–29 N·m (18–21 lb ft). 14. Install the turbine hub sealring 16 onto turbine assembly 17. Install the turbine hub assembly 17 into torque converter cover assembly 6 aligning balance mark on the turbine with the balance mark on the lockup clutch damper. 15. Install stator assembly 20.

CAUTION: When installing thrust bearings, make sure that the locating lip on either the inner or outer thrust bearing race is not preventing the race from contacting the thrust surface of the mating part. Failure to do this leads to premature thrust bearing failure and incorrect shim selection to maintain proper internal part clearance. 6. Install thrust bearing assembly 18. 7. If removed, press a new bushing 8 into cover 7 bushing bore using J 39949 bushing installer and J 8092 drive handle. 8. Install new sealring 16 onto turbine hub and insert turbine assembly 17 into the new bushing and inspect for freedom of rotation.

5–2

V01360.03.00

16. If removed, install thirty-six T-head bolts 34 into the flange of converter pump assembly 33. If removed, install pump thrust bearing race 32 into torque converter pump assembly 33. 17. Install O-ring 31 onto converter cover assembly 6. With balance marks or scribe mark aligned, place converter pump assembly 33 over the top of converter cover assembly 6. 18. Install four nuts 5, evenly spaced, onto four T-head bolts 34. Tighten the nuts to 30–35 N·m (22–26 lb ft). 19. Using a depth micrometer, measure from the top of the drive tang surface to the thrust surface of the turbine hub. This is dimension A (Figure 5–2).


MODULE REBUILD DRIVE TANG SURFACE THRUST SURFACE OF TURBINE HUB

DIM.

SHIM (30) LOCATION

DRIVE TANG SURFACE

DIM.

THRUST SURFACE OF TURBINE HUB

A

B

J 38548

E02517.01

Figure 5–2. Torque Converter Selective Shim

26. Perform the measurement again. Dimension C must be 0.08–0.36 mm (0.003–0.014 inch). If dimension C is correct, proceed with Step (28).

20. Turn the converter on its side and insert tool J 38548, with bolt removed, into the converter plug bore. Turn the torque converter so that it rests on tool J 38548. Repeat the same measurement as in Step (19). This is dimension B.

27. If dimension C is not correct, then a shim change is needed. Disassemble the converter and reassemble without shim 28, and go back to Step (18).

21. Subtract dimension B from dimension A to get dimension C (A–B=C). 22. Dimension C must be 0.08–0.36 mm (0.003– 0.014 inch). If dimension C is correct, proceed with Step (28).

28. Install the remaining thirty-two nuts 5 onto T-head bolts 34. Tighten all the nuts to 30–35 N·m (22–26 lb ft).

23. If dimension C is not correct, then a shim is needed. Select the proper shim from Table 5–1 and proceed with Step (24).

NOTE:

24. Disassemble the converter and reassemble using selected shim.

• For models without PTO provision, proceed

with Paragraph 5–4.

25. Install four nuts 5, evenly spaced, onto four T-head bolts 34. Tighten the nuts to 30–35 N·m (22–26 lb ft).

• For models with PTO provision, skip Para-

graph 5–4 and proceed with Paragraph 5–5.

Table 5–1. Torque Converter Selective Shims Dimension C

Use P/N

Shim Thickness

0.08–0.36 mm (0.003–0.014 inch)

—

—

0.36–0.58 mm (0.014–0.023 inch)

29503879

0.23–0.27 mm (0.009–0.011 inch)

0.58–0.81 mm (0.023–0.032 inch)

29503880

0.46–0.48 mm (0.018–0.019 inch)

0.81–0.99 mm (0.032–0.039 inch)

29503881

0.69–0.711 mm (0.027–0.028 inch)


5–3

4000 PRODUCT FAMILY SERVICE MANUAL 5–4.

TORQUE CONVERTER HOUSING MODULE (Models Without PTO Provision)

a. Disassembly (Foldout 5,A) 1. If not previously removed, remove bolt 7, speed sensor retainer 6, and engine speed sensor assembly 4. Measure engine speed sensor resistance (speed sensor resistance varies by temperature). Resistance (Ohms) Temperature (°C) Temperature (°F) 250

–40

–40

340

20

68

450

110

230

CAUTION: Use the correct wrench size to avoid crushing the vent assembly.

b. Assembly (Foldout 5,A) 1. Install engine speed sensor assembly 4, speed sensor retainer 6, and bolt 7. Tighten the bolt to 24–29 N·m (18–21 lb ft).

CAUTION: Use the correct wrench size to avoid crushing the vent assembly. 2. Install breather assembly 2. Torque breather assembly to 12–16 N·m (9–12 lb ft).

4. Remove eleven bolts 2 holding bearing retainer assembly 3 and PTO gear assembly 10 into converter housing 19. 5. Remove bearing retainer assembly 3 and PTO gear assembly 10. If necessary, use jack bolts to loosen the bearing retainer assembly. b. Disassembly of Bearing Retainer (Foldout 5,B) 1. Remove sealrings 8 and 9 from bearing retainer 7. Remove oil seal assembly 4 using tool J 24171-A. 2. Inspect bushing 6 for damage or wear. Maximum allowable bushing ID is 89.19 mm (3.511 inch). Remove the bushing if damaged or worn.

1. Remove oil pump drive hub 13 from PTO gear 12. 2. Inspect oil pump drive hub for excessive wear on drive tangs. Maximum allowable tang wear is 0.31 mm (0.012 inch). 3. Remove sealring 14 from PTO gear 12. If damaged, press two bearings 11 from PTO gear 12. d. Assembly of PTO Gear Assembly (Foldout 5,B) 1. Press two bearings 11 onto the PTO gear using tool J 37041.

3. Skip to Paragraph 5–6.

TORQUE CONVERTER HOUSING MODULE (Models With PTO Provision)

a. Disassembly (Foldout 5,B) 1. If not previously removed, remove bolt 18, speed sensor retainer 17, and engine speed sensor assembly 15. The engine speed sensor must have a resistance of 300 ± 30 Ohms.

CAUTION: Use the correct wrench size to avoid crushing the vent assembly. 5–4

3. If present, remove ten bolts 24 or 27, PTO cover 25 or 28, and gasket 26 or 29.

c. Disassembly of PTO Gear Assembly (Foldout 5,B)

2. Remove breather assembly 2.

5–5.

2. Remove breather assembly 20.

CAUTION: Oil pump drive hub 13 can be incorrectly installed backwards—position the oil pump drive hub tangs toward the oil pump. 2. Install oil pump drive hub 13 into PTO gear 12, aligned with hub tangs toward the oil pump. 3. Insert sealring 14 into the sealing bore of pump housing 10 (Foldout 6,A) and measure end gap with feeler gauges. Sealring end gap must be 1.18–1.66 mm (0.047–0.065 inch). Refer to Paragraph 3–6h.


MODULE REBUILD 4. Remove sealring 14 (Foldout 5,B) from the seal bore and install the sealring onto PTO gear 12. e. Assembly of Bearing Retainer Assembly (Foldout 5,B) 1. If removed, install bushing 6 using a press, and tools J 37038 and J 8092. 2. Install sealring 9 onto bearing retainer 7. Install oil seal 4 using a press, and tools J 37032 and J 37034. 3. Insert sealring 8 into the sealing bore in PTO gear 12 and measure the end gap using feeler gauges. Sealring end gap must be 1.18–1.66 mm (0.047–0.065 inch). Refer to Paragraph 3–6h. 4. Remove sealring 8 from sealing bore and install the sealring onto bearing retainer 7. f. Assembly (Foldout 5,B) 1. Using a mallet, lightly tap PTO gear assembly 10 into converter housing 19 until the gear assembly is seated. 2. Use guide bolts to install bearing retainer assembly 3, rocking the retainer while installing it. 3. Install eleven bolts 2 to hold bearing retainer assembly 3 and PTO gear assembly 10 to housing 19. Tighten the bolts to 51–61 N·m (38–45 lb ft). 4. If used, install PTO covers 25 or 28 and gaskets 26 or 29 using ten bolts 24 or 27 in the cover. Tighten the bolts to 51–61 N·m (38–45 lb ft). 5. Install engine speed sensor assembly 15 and engine speed sensor retaining bolt 18. Tighten the bolt to 24–29 N·m (18–21 lb ft).

CAUTION: Use the correct wrench size to avoid crushing the breather. 6. Install breather 20. Tighten the breather to 12–16 N·m (9–12 lb ft).

5–6.

FRONT SUPPORT AND OIL PUMP MODULE

a. Disassembly (Foldout 6,A) 1. Remove three sealrings 25 from the hub of front support 20. 2. Remove eight bolts 6 retaining pump housing assembly 7 or 10 (PTO unit) to front support assembly 15. 3. Remove pump housing assembly 7 or 10 and gear set 11. 4. On models without PTO, remove O-ring 4 and oil seal assembly 5 using tool J 24171-A. 5. Measure gear-cavity depth of pump housing 9 or 10. Maximum depth allowed is 19.04 mm (0.750 inch) (Figure 5–3). 6. Measure gear-cavity diameter of pump housing 9 or 10. Maximum ID allowed is 150.25 mm (5.915 inch) (Figure 5–4). 7. For models without PTO provision, inspect bushing 8 inside pump housing 9 for wear or damage. Measure the ID of the pump bushing. Maximum ID allowed is 89.19 mm (3.511 inch). 8. If worn or damaged, remove bushing 8 from pump housing 9. 9. Install gear set 11 into pump housing 9. Measure pump gear side clearance of both gears. Maximum allowable clearance is 0.10 mm (0.004 inch) (Figure 5–5).


5–5

4000 PRODUCT FAMILY SERVICE MANUAL

PUMP HOUSING

MAX DEPTH OF GEAR CAVITY 19.04 mm (0.75 in.)

PUMP HOUSING

DRIVE GEAR MAX SIDE CLEARANCE 0.10 mm (0.004 in.)

DRIVEN GEAR V02518

V01899.01

Figure 5–3. Measuring Gear-Cavity Depth of the Pump Housing

Figure 5–5. Measuring Gear Side Clearance of the Pump Housing

PUMP HOUSING

MAX GEAR TOOTH TIP CLEARANCE 0.15 mm (0.006 in.)

MAX ID OF GEAR CAVITY 150.25 mm (5.915 in.)

V02519

V01277.01

Figure 5–6. Measuring Gear Tooth Tip Clearance Figure 5–4. Measuring Gear-Cavity Diameter of the Pump Housing

10. Measure gear tooth tip clearance. Maximum allowable clearance is 0.15 mm (0.006 inch) (Figure 5–6). 11. Measure driven gear to pump housing clearance. Maximum clearance allowed is 0.30 mm (0.012 inch) (Figure 5–7). 12. Inspect bushing 12 that is inside the inner (drive) gear of gear set 11. Measure the ID of bushing 12. The maximum allowable ID is 66.93 mm (2.635 inch). 13. If bushing 12 is damaged or worn, remove the bushing. 5–6

PUMP HOUSING DRIVEN GEAR

MAX CLEARANCE BETWEEN DRIVEN GEAR OD AND PUMP HOUSING 0.30 mm (0.012 in.) V02520

Figure 5–7. Measuring Driven Gear Clearance to the Pump Housing


MODULE REBUILD 14. Remove fourteen bolts 14 retaining the wear plate 13 to front support 20. Remove wear plate 13. 15. If damaged, remove roller bearing 26 from front support 20 using a drift and hammer. 16. Measure the OD of front support sleeve 21. Minimum diameter is 119.81 mm (4.717 inch). Also inspect for wear. If worn or damaged, remove front support sleeve 21 from front support 20. 17. If damaged, remove dowel pins 19 from front support 20. 18. If worn or damaged, remove ground sleeve 16 or 17 by pressing ground sleeve from front support 20. 19. Compress spring 22, using tool J 41462, until load is removed from dowel pin 24. Remove dowel pin 24 and carefully release the load on spring 22 by rotating the handle on tool J 41462 in the counter-clockwise direction. When spring 22 has reached its free length, remove tool J 41462. Remove spring 22 and ball 23 from the front support 20.

4. If removed, install ground sleeve 16 or 17. Place front support 20 on press bed. The machined flat at the base of the ground sleeve must align with the arrow “↑” cast on the front support (Figure 5–8, View C). Press ground sleeve 16 or 17 into front support 20 to shoulder. Total runout of spline OD may not exceed 0.13 mm (0.005 inch). 5. If removed, install dowel pins 19. Press the pins to a height of 14.5 mm (0.57 inch) from the surface of front support 20. 6. If removed, align the lubrication hole in sleeve 21 with the relief valve bore (bottom of front support), and install front support sleeve 21 using a press and tools J 37041 and J 37034. Refer to Figure 5–8, View B. 7. Install wear plate 13. Secure with fourteen bolts 14. Tighten the bolts to 51–61 N·m (38–45 lb ft). 8. Install bearing 26 using a press, and tools J 37038 and J 8092. Press bearing 26 flush to 0.25 mm (0.010 inch) below the surface. c. Assembly of Pump Housing (Foldout 6,A) NOTE:

20. Inspect for damage in the ball seat area of front support 20. Measure tension of spring 22 and compare to value in Table 7–2, Spring Data, in Section 7. b. Assembly of Front Support (Foldout 6,A and Figure 5–8) 1. Replace front support 20 if damage to the ball seat or other area was found.

Steps (1), (2), and (3) below apply only to transmissions without PTO provision. 1. If removed, install bushing 8 into pump housing 9 using a press, and tools J 37038 and J 8092. 2. Install oil seal 5 using a press, and tools J 37032 and J 37034. 3. Install O-ring 4.

2. Replace spring 22 if spring load did not meet load specifications. 3. Install ball 23 and spring 22 into front support 20. Compress spring 22 using tool J 41462 until dowel pin 24 can be inserted to retain spring 22. Remove tool J 41462.

4. If removed, install bushing 12 into drive (inner) gear of gear set 11. Align the staking in the pre-staked bushing with the slots in the inside gear of gear set 11. Use tool J 39954. 5. Lubricate pump gear set 11 and install the gear set in pump housing 9 or 10.


5–7

4000 PRODUCT FAMILY SERVICE MANUAL FRONT TOP

FRONT SUPPORT (20) DOWEL PINS (19 )

DOWEL PIN

E

14.5 mm (0.57 in.)

GROUND SLEEVE

INSTALL

REMOVE

SPLINE OD T.I.R. 0.30 mm (0.012 in.)

E SECTION E-E BOTTOM

VIEW A

RELIEF VALVE BORE

VIEW B To install, align flat on ground sleeve with arrow on front support.

GROUND SLEEVE (16 OR 17)

20

VIEW C

V01344.00.04

Figure 5–8. Ground Sleeve Removal and Installation

6. Retain the pump housing to the front support with eight bolts 6. Tighten the bolts to 51–61 N·m (38–45 lb ft). 7. Measure the end gap of three rotating sealrings 25 before installation. Insert the sealrings into the rotating clutch hub bore and measure end gap with a feeler gauge. Sealring end gap must be 1.00–1.44 mm (0.040–0.056 inch). Refer to Paragraph 3–6h. 8. Install three rotating sealrings 25 on front support 20 hub.

5–8

5–7.

ROTATING CLUTCH MODULE

a. Disassembly (Foldout 6,B) 1. Remove internal retaining ring 43. 2. Remove P1 sun gear assembly 41. 3. Inspect thrust bearing 42 for wear. Replace the bearing if it is worn. 4. Remove C2 internal retaining ring 40. 5. Remove C2 clutch backplate 39.


MODULE REBUILD 6. Measure the wear surface thickness of C2 clutch backplate 39. Minimum thickness allowed is 7.90 mm (0.311 inch). Measure flatness of the backplate. Maximum allowable distortion is 0.15 mm (0.006 inch). 7. Remove C2 clutch pack—seven friction plates 38 and seven steel reaction plates 37. 8. Measure the thickness of each friction plate 38. Minimum thickness allowed is 2.92 mm (0.115 inch). Measure the oil groove depth and cone of each friction plate. Minimum groove depth allowed is 0.20 mm (0.008 inch). Maximum cone allowed is 0.25 mm (0.010 inch).

depth allowable is 0.20 mm (0.008 inch). Maximum cone allowed is 0.25 mm (0.010 inch). 14. Measure the thickness of each steel reaction plate 31. Minimum allowable thickness is 2.41 mm (0.095 inch). Maximum cone allowable is 0.25 mm (0.010 inch). 15. Measure the wear surface thickness and cone of C1 clutch apply plate 29 and backplate 32. Minimum thickness allowed is 5.90 mm (0.232 inch) and 9.90 mm (0.390 inch), respectively. Measure flatness of the C1 clutch apply plate and backplate. Maximum allowable distortion is 0.15 mm (0.006 inch).

9. Measure the thickness and cone of each steel reaction plate 37. Minimum thickness allowed is 2.41 mm (0.095 inch). Maximum cone allowable is 0.25 mm (0.010 inch).

16. Remove thrust bearing 14 from rotating clutch hub assembly 11.

10. Remove C2 drive hub 36, including two thrust bearings 35. Inspect the splines of the C2 drive hub. Maximum spline wear allowed is 0.38 mm (0.015 inch).

18. Inspect bushing 5 inside the end of turbine shaft 4 or 7. Measure the ID of the turbine shaft bushing. Maximum ID allowed is 36.14 mm (1.423 inch).

11. Remove C1 drive hub 34. Inspect the splines of the C1 drive hub. Maximum allowable spline wear is 0.38 mm (0.015 inch).

19. Remove three rotating sealrings 8.

12. Remove C1 external retaining ring 33 and C1 clutch pack—one backplate 32, seven friction plates 30 and six steel reaction plates 31, and one apply plate 29. 13. Measure the thickness of each friction plate 30. Minimum allowable thickness is 2.92 mm (0.115 inch). Measure the oil groove depth and cone of each friction plate. Minimum groove

17. Remove retaining ring 15 and turbine shaft assembly 3 or 6.

20. Remove O-ring assembly 3 or 6.

2

from

turbine

shaft

21. Place rotating clutch on tool base J 37030-3 so rotating drum is supported by tool tangs (Figure 5–9, View C). Install J 35923-2 (Figure 5– 9, View A), including the bearing, washer and handle. Tighten tool, compressing C1 balance piston 26 and C1 return spring assembly 25, and remove the balance piston retaining ring 28.


5–9

4000 PRODUCT FAMILY SERVICE MANUAL J 37030-3

J 37030-3

HANDLE

HANDLE

FLAT WASHER

FLAT WASHER

BEARING

J 35923-2

BEARING

J 35923-2

VIEW A

VIEW B

J 37030-3 VIEW C VIEW D

ALIGNMENT SLOTS

V06847.02.00

Figure 5–9. Rotating Clutch Disassembly/Assembly

25. Remove C2 spring assembly 20.

WARNING! Carefully release spring force. Piston springs are highly compressed. Personal injury can occur if the spring force is not controlled. 22. Release spring force by rotating handle in counterclockwise direction. Remove handle, flat washer, bearing, and J 35923-2 tool. 23. Remove balance piston 26, sealring 27, and C1 spring assembly 25. 24. Install tools J 37030-3, J 37030-1, J 35923-2 (Figure 5–9, View B), bearing, washer, and handle. Tighten tool and remove internal retaining ring 22. Remove tools after relieving spring force. 5–10

26. Lift rotating clutch drum 9 free of rotating clutch hub 13 and C1/C2 pistons 24 and 19. Inspect the clutch splines of the rotating drum. Maximum spline wear allowed is 0.38 mm (0.015 inch). 27. Remove C1/C2 pistons 24 and 19 and sealrings 18 and 23 from hub assembly 11 rocking the piston from side to side. 28. Inspect the ID of rotating clutch hub bushing 12. Maximum allowable ID of the bushing is 120.27 mm (4.735 inch). Remove the bushing from hub assembly 11 if replacement is necessary. Avoid damaging the bushing bore.


MODULE REBUILD 29. Remove piston sealrings 16 and 17 from hub 13. 30. Separate C1 piston 24 and sealring 23 from C2 piston 19 and sealring 18 by tapping lightly on the C1 piston. b. Assembly Foldout 6,B) 1. If removed during disassembly, install bushing 12 into drive hub assembly 11 using tools J 37040 and J 8092. 2. Install piston sealring 16 on hub assembly 13 and piston sealring 18 into C2 piston 19. Install piston sealring 17 on rotating clutch hub assembly 13 and piston sealring 23 onto C1 piston 24. 3. With a mallet, lightly tap C2 piston 19 (with sealring 18) onto hub assembly 11. 4. Align notch on C1 piston with any lubrication orifice on the rotating drive hub. With a mallet, lightly tap C1 piston 24 (with sealring 23) onto the center of C2 piston 19 and over rotating clutch hub assembly 13. 5. Install rotating clutch drum 9 over hub assembly 11 and C1/C2 pistons 24 and 19. 6. Install C2 spring assembly 20. Align the spring assembly with the rotating clutch hub 36 tangs and the splines on the C2 piston 19. The C2 spring assembly must make contact with the bottom of the slots in the C2 piston. If the spring assembly does not reach the bottom, remove the C2 spring assembly and re-index it in the next spline on the rotating drum 9. Repeat this process until the C2 spring assembly is in the proper position. 7. Install C2 spring plate 21. Index the spring plate with the drive hub tangs and the splines on the C2 piston. 8. Place the rotating clutch on tool base J 37030-3 so that the rotating drum is supported by tool tangs. Install tool J 37030-1 (Figure 5–9, View B), J 35923-2, that includes the bearing, washer, and handle. Tighten tool to compress C2 spring assembly 20, and install retaining ring 22. Remove tools. 9. Install sealring 27 onto balance piston 26.

10. Install C1 spring assembly 25. Aligning mark on balance piston with slot on the C1 clutch piston, install balance piston 26 onto the C1 piston. 11. Install tool J 35923-2 (Figure 5–9, View A), that includes the bearing, washer, and handle. Tighten tool to compress C1 spring assembly and install retaining ring 28 into the hub of the rotating clutch assembly. Remove tool. 12. If removed, install bushing 5 into turbine shaft assembly 3 or 6 using tools J 37036 and J 8092. 13. Install O-ring 2 onto the forward end of the turbine shaft. 14. Install each rotating sealring 8 into the ground sleeve bore and measure the end gap. Sealring end gap must be 0.65–1.01 mm (0.026–0.039 inch). Refer to Paragraph 3–6h. Install three rotating sealrings 8, with correct end gap, onto the rear of the turbine shaft. 15. Install turbine shaft assembly 3 or 6. Retain the turbine shaft with retaining ring 15.

CAUTION: Be sure that thrust bearings are assembled to function correctly. Make sure that the locating lip on either the inner or outer thrust bearing race is not preventing the race from contacting the thrust surface of the mating part. Failure to do this leads to premature thrust bearing failure and incorrect shim selection to maintain proper internal part clearance. 16. Install thrust bearing 14 onto the rotating clutch hub assembly 13. 17. Install C1 clutch pack (Figure 5–10)—one clutch apply plate 29, seven friction plates 30, six steel reaction plates 31, and one backplate 32. Install clutch plates alternately, starting with a friction plate 30. Install C1 retaining ring 33. 18. Install C1 drive hub 34. Be sure that the drive hub passes over the external splines of all seven plates 30. 19. Install a thrust bearing 35 on each side of C2 drive hub 36, and install this assembly over C1 drive hub 34.


5–11

4000 PRODUCT FAMILY SERVICE MANUAL 20. Install C2 clutch plates—seven friction plates 38 and seven steel reaction plates 37. Install clutch plates alternately, starting with a steel reaction plate 37. 21. Install C2 backplate 39. Install C2 retaining ring 40. 22. If removed, install thrust bearing 42 on sun gear assembly 41. 23. Install P1 sun-gear drive hub 41. Install retaining ring 43.

5–8.

C3/C4 AND MAIN HOUSING MODULE

a. Disassembly (Foldout 7) NOTE: When replacing a nameplate, keep the original identification plate. Stamp the information from the original identification plate onto the replacement identification plate. 1. Replace a damaged nameplate—remove retaining rivet 24 and nameplate 23. 2. Inspect the inner C5 clutch plate splines of main housing 31. Maximum allowable spline wear is 1.15 mm (0.045 inch). 3. Remove fourteen bolts 2 retaining the C3 backplate assembly 3 and C3 clutch housing

assembly 11. assembly 3.

Remove

C3

4. Inspect four thrust plates 5 and clutch backplate 4. Minimum allowable thrust plate 5 thickness at the contact surface is 2.82 mm (0.111 inch). Maximum allowable distortion of backplate 4 is 0.15 mm (0.006 inch). Maximum allowable step wear of backplate 4 is 0.13 mm (0.005 inch). 5. Remove P1 ring gear 6. Inspect the clutch splines of the P1 ring gear. Maximum allowable spline wear is 0.38 mm (0.015 inch). 6. Remove the C3 clutch pack—five friction plates 7 and five steel reaction plates 8. 7. Measure the thickness and cone of each friction plate 7. Minimum thickness is 3.485 mm (0.137 inch). Maximum allowable cone is 0.25 mm (0.010 inch). 8. Measure the thickness and cone of each steel reaction plate 8. Minimum allowable thickness is 3.25 mm (0.128 inch). Maximum allowable cone is 0.25 mm (0.010 inch). 9. Remove piston return plate assembly 9. 10. Inspect plate 9. Minimum allowable thickness of plate 9 is 4.91 mm (0.193 inch). Replace if damaged. 11. Remove C3 housing assembly 11.

CLUTCH APPLY PLATE

BACKPLATE

V05566.00.01

Figure 5–10. C1 Apply Plate and Backplate

5–12

backplate


MODULE REBUILD 12. Inspect six thrust plates 12 in C3 housing 13. Minimum allowable thrust plate 12 thickness at the contact surface is 2.82 mm (0.111 inch). Maximum allowable distortion of backplate 4 is 0.15 mm (0.006 inch). Maximum stepwear of 0.13 mm (0.005 inch) is allowed. If replacement is necessary, remove the thrust plates. Inspect splines in C3 clutch housing 13. Maximum spline wear allowed is 1.15 mm (0.045 inch). 13. Remove C4 clutch pack—six steel reaction plates 14 and five friction plates 15.

tightly attached to the housing; no movement is allowed. 5. Install C3 clutch piston 10 into C3 clutchhousing assembly 13. 6. Install C3 clutch housing assembly 11 with clutch piston 10 on top of the assembled C4 clutch housing assembly. Make sure index notches on the clutch housings are aligned. 7. Install piston return plate 9. 8. Install P1 ring gear 6.

14. Measure the thickness and cone of each friction plate 15. Minimum allowable thickness is 3.485 mm (0.137 inch). Maximum allowable cone is 0.25 mm (0.010 inch).

9. Install the C3 clutch pack. Starting with a friction plate, alternately install five friction plates 7 and five steel reaction plates 8.

15. Measure the thickness and cone of each steel reaction plate 14. Minimum allowable thickness is 3.25 mm (0.128 inch). Maximum allowable cone is 0.25 mm (0.010 inch).

10. To assemble the C3 backplate (if thrust plates were removed), install six thrust plates 5 into C3 backplate 4. The thrust plate must be tightly attached to the housing; no movement is allowed.

16. Remove piston return plate assembly 16. Inspect plate 16. Minimum allowable thickness of plate 23 is 4.91 mm (0.193 inch)

11. Install C3 backplate assembly 3. Align the notch on the C3 backplate with the notches on the C3 and C4 housings.

17. Remove piston 17 from C4 housing 18. Inspect splines in C4 clutch housing 18. Maximum spline wear allowed is 1.15 mm (0.045 inch).

12. Install fourteen retaining bolts 2 into the C3/C4 clutch assembly. Tighten the bolts to 51–61 N·m (38–45 lb ft). 13. If removed, install nameplate 23 and screw 24.

b. Assembly (Foldout 7) 1. Install piston 17 into C4 housing 18. 2. Install piston return plate assembly 16.

5–9.

MAIN SHAFT MODULE

a. Disassembly (Foldout 8)

3. Install C4 clutch pack. Starting with a friction plate—alternately install five friction plates 15 and six steel reaction plates 14.

1. Remove external spiral retaining ring 4.

4. To assemble the C3 housing (if thrust plates were removed), install six thrust plates 12 into C3 clutch housing 13. The thrust plate must be

3. Remove bearing spacer 6.

2. Remove P2 sun gear 5.

4. Remove thrust bearing 2.


5–13

4000 PRODUCT FAMILY SERVICE MANUAL 5. Remove selective shim 1. On 4700 and 4800 models, remove non-selective shim 1. 6. On close ratio transmissions, remove P3 sun gear 7 from main shaft 8. 7. For all models, inspect main shaft 7 or 8 for wear, damage, and evidence of chipped or cracked splines or gear teeth. Measure the journals as illustrated in Figure 5–11. Maximum main shaft spline wear is 0.38 mm (0.015 inch). b. Assembly (Except 4700 and 4800 Models) (Foldout 8) NOTE: Do not install thrust bearing 2 or selective shim 1 until final transmission assembly. Measurement for selective shim 1 is performed during final buildup. 1. On close ratio transmissions, install P3 sun gear 7 onto main shaft 8. 2. Install bearing spacer 6. 3. Install P2 sun gear 5.

5–10. P1 PLANETARY MODULE a. Disassembly (Foldout 9,A) 1. Remove internal retaining ring 2 from P2 ring gear 15. 2. Remove P2 ring gear 15. 3. Measure P1 planetary carrier assembly 3 pinion end play. Pinion end play must not exceed 0.94 mm (0.037 inch). Measure all six pinion gears. 4. Remove retaining ring 4. Remove indexing ring 5. 5. Remove six pinion spindles 6 from P1 carrier 8. 6. Slide pinion gear 11, thrust washers 10 and 13, and two bearing assemblies 12 from the side of P1 planetary carrier 8. Repeat the procedure with the five remaining pinion gears. 7. Measure the thickness and any step wear for all thrust washers 10 and 13. Minimum thrust washer thickness allowed is 1.40 mm (0.055 inch). Maximum allowable step wear is 0.12 mm (0.005 inch).

4. Install external spiral retaining ring 4 c. Assembly (4700 and 4800 Models) (Foldout 8) 1. Install P3 sun gear 7 onto main shaft 8. 2. Install bearing spacer 6. 3. Install P2 sun gear 5. 4. Install external spiral retaining ring 4. 5. Install non-selective shim 1. 6. Install thrust bearing 2. 35.92 mm (1.414 in.)

9. Inspect bushing 9 inside P1 planetary carrier 8 for wear or damage. Maximum ID allowed is 89.32 mm (3.516 inch). If worn, remove bushing 9. 10. Determine if there is spline wear between P1 planetary carrier 8 and P2 planetary ring gear 15. Maximum allowable spline wear is 0.38 mm (0.015 inch). b. Assembly (Foldout 9,A)

52.98 mm (2.085 in.) 35.92 mm (1.414 in.)

V02524

Figure 5–11. Measurement of Main Shaft Journals

5–14

8. Remove thrust bearing assembly 14 from P1 planetary carrier 8.

1. If replacement is necessary, press a new bushing 9 into P1 carrier 8 using a press, installer J 37038, and drive handle J 8092. Press bushing 9 flush to 0.40 mm (0.016 inch) below the surface. 2. Install two bearing assemblies 12 into the center of pinion gear 11. Install thrust washers 10 and 13 inside P1 planetary carrier 8, align thrust washer tangs with the


MODULE REBUILD slots in the planetary, and retain them with oilsoluble grease. 3. Slide the pinion gear and bearing assemblies into the side of the P1 planetary carrier between the thrust washers. 4. Repeat the procedure for the five remaining pinion gears. 5. Install six spindles 6 so the lower step is positioned for proper installation of indexing ring 5. 6. Install indexing ring 5 and retaining ring 4. 7. If components were replaced, measure pinion end play. Pinion end play must not exceed 0.94 mm (0.037 inch). Measure all six pinion gears. 8. Install P2 ring gear 15 over P1 planetary carrier assembly 3. 9. Install internal retaining ring 2 into P2 ring gear 15, connecting P1 planetary carrier assembly 3 and the P2 planetary ring gear.

CAUTION: Be sure that thrust bearings are assembled to function correctly. Make sure that the locating lip on either the inner or outer thrust bearing race is not preventing the race from contacting the thrust surface of the mating part. Failure to do this leads to premature thrust bearing failure and incorrect shim selection to maintain proper internal part clearance. 10. Install thrust bearing assembly 14 on P1 planetary carrier assembly 3.

5–11. P2 PLANETARY MODULE a. Disassembly (Foldout 9,B) 1. Remove retaining ring 2. 2. Remove P3 ring gear 15. Remove and inspect thrust bearing assembly 14. 3. Measure P2 planetary carrier pinion end play. Pinion end play must not exceed 0.94 mm (0.037 inch). Measure all four pinion gears.

4. Remove internal retaining ring 4. Remove indexing ring 5. Remove four pinion spindles 13 from P2 carrier 7. 5. Slide a pinion gear 11, thrust washers 9 and 12, and two roller bearings 10 from the side of P2 planetary carrier 7. Repeat the procedure with the three remaining pinion gears. 6. Measure the thickness and any step wear for all thrust washers 9 and 12. Minimum allowable thickness of the thrust washers is 1.40 mm (0.055 inch). Maximum allowable step wear is 0.12 mm (0.005 inch). 7. Inspect bushing 8 inside P2 planetary carrier 7 for wear or damage. Maximum ID of the bushing is 53.23 mm (2.096 inch). Remove bushing 8 if it is worn or damaged. 8. Determine whether there is spline wear between P2 planetary carrier 7 and P3 planetary ring gear 15. Maximum wear allowed is 0.38 mm (0.015 inch). b. Assembly (Foldout 9,B and Figure 5–12) 1. If replacement is necessary, press a new bushing 8 into P2 carrier 7 using a press, installer J 37036, and driver J 8092. 2. Install two roller bearings 10 into the center of pinion gear 11. Install thrust washers 9 and 12 in P2 planetary carrier 7, align thrust washer tangs with slots in the planetary, and retain them with oil-soluble grease. Slide the pinion gear and two bearing sets, into the side of the P2 planetary carrier between the thrust washers. Repeat the procedure with the three remaining pinion gears.

CAUTION: If the wear on the indexing ring is minor, flip it over to get a fresh reaction point for the spindle. Replace the indexing ring if both corners of the indexing ring are worn. Failure to take corrective action may allow the spindle to rotate which may reduce or shut off lubrication to the pinion bearings and thrust washers. 3. Install four spindles 13 so the lower step is positioned for proper installation of indexing ring 5. 4. Install indexing ring 5 and internal retaining ring 4.


5–15

4000 PRODUCT FAMILY SERVICE MANUAL

DIMENSION A

VIEW A

VIEW B V06848

Figure 5–12. Planetary Spindle and Indexing Ring

5. If components were replaced, measure pinion end play. Pinion end play must not exceed 0.94 mm (0.037 inch). Measure all four pinion gears. Install thrust bearing 14. 6. Install thrust bearing 14. 7. Install P3 ring gear 15 over P2 carrier assembly 3. 8. Install retaining ring 2 into P3 ring gear 15 so that the P2 carrier and P3 ring gear are linked. NOTE: • For 4000 Product Family models with retarder (except 4700 and 4800 models) proceed to Paragraph 5–14. • For 4000 Product Family models without retarder (except 4700 and 4800 models) skip Paragraph 5–14 and 5–15 and proceed to Paragraph 5–16.

5–12. P3 PLANETARY MODULE (4700 and 4800 Models) a. Disassembly (Foldout 9,C) 1. Measure pinion end play of P3 carrier assembly 1. Pinion end play must not exceed 0.94 mm (0.037 inch). Measure the three remaining pinion gears 9.

5–16

2. Remove internal retaining ring 2. Remove indexing ring 3. Remove four planetary spindles 7. 3. Slide pinion gear 9, thrust washers 8, and two bearing assemblies 10 from the side of P3 planetary carrier 4. Repeat the procedure for three remaining pinion gears. 4. Measure the thickness and any step wear for eight thrust washers 8. Minimum allowable thickness of the thrust washers is 1.40 mm (0.055 inch). Maximum step wear allowed is 0.12 mm (0.005 inch). b. Assembly (Foldout 9,C) 1. Install two roller bearing assemblies 10 into the center of pinion gear 9. Install thrust washers 8 in P3 planetary carrier 4, align the thrust washer tangs with the slots in the carrier, and retain them with oil-soluble grease. Slide the pinion gear and bearings into the side of the P3 planetary carrier between the thrust washers. Repeat the procedure with the three remaining pinion gears. 2. Install four planetary spindles 7 so the lower step is positioned for proper installation of indexing ring 3. 3. Install indexing ring 3. Install internal retaining ring 2.


MODULE REBUILD 4. If components were replaced, measure pinion end play. Pinion end play must not exceed 0.94 mm (0.037 inch). Measure all four pinion gears 9. NOTE: Do not install shim locating ring 6 or selective shim 12 until final transmission assembly. Measurement for selective shim is performed during final buildup.

5–13. C6 ADAPTER HOUSING MODULE (4700 and 4800 Models) (Foldout 9,C) a. Disassembly of Ring Gear and Hub Assembly 1. Remove P4 ring gear and hub assembly 45. 2. Remove retaining ring 48 from P4 ring gear and hub assembly 45 and separate P4 ring gear 46 and P4 ring gear hub 47.

7. Remove twelve thrust washers 40 and twelve caged needle bearings 42 from the pinion gears. 8. Measure the thickness and any step wear for twelve thrust washers 40. Minimum allowable thickness of the thrust washers is 1.40 mm (0.055 inch). Maximum step wear allowed is 0.12 mm (0.005 inch). 9. Inspect bushing 38 in carrier 37 for wear or damage. Maximum allowable bushing ID is 113.33 mm (4.462 inch). Remove bushing 38 if it is worn or damaged. d. Disassembly of Remaining C6 Parts 1. Lift C6 clutch pack from C6 adapter housing assembly—eight friction plates 28 and nine reaction plates 27. 2. Measure the thickness and cone of each friction plate 28. Minimum thickness is 3.68 mm (0.145 inch). Maximum allowable cone is 0.25 mm (0.010 inch). 3. Measure thickness and cone of each steel reaction plate 27. Minimum thickness is 3.24 mm (0.128 inch). Maximum allowable cone is 0.25 mm (0.010 inch).

3. Remove thrust bearing 44. b. Disassembly 1. Remove C6 backplate 29. 2. Thread three M8 eye bolts into the three tapped holes of P4 planetary carrier assembly 32. 3. Attach hoist and remove P4 planetary carrier assembly 32 from C6 adapter housing 22.

4. Remove thrust bearing 31. 5. Remove P4 sun gear 30. 6. Place special tool J 43025 onto return spring assembly 17 (Figure 5–13).

c. Disassembly of P4 Planetary Carrier Assembly 1. Remove internal retaining ring 33 from C6 clutch drum hub 43. 2. Turn over P4 carrier assembly and remove clutch drum hub 43.

J 35923

J 43025

3. Remove internal retaining ring 34 and indexing ring 35 from P4 carrier assembly 32. 4. Remove six spindles 39 from P4 carrier 37. 5. Measure pinion end play. Pinion end play must not exceed 0.94 mm (0.037 inch). Measure the five remaining pinion gears. 6. Remove six P4 pinion gears 41 from P4 carrier assembly 32.

V05581

Figure 5–13. Compressing Spring and Retainer Assembly


5–17

4000 PRODUCT FAMILY SERVICE MANUAL 7. Compress return spring assembly 17 using J 35923-4 tool base, washer, bearing, handle, and piston spring compressor J 43025 (Figure 5–14). Remove external retaining ring 16 and slowly release the spring force. 8. Remove piston return spring assembly 17. 9. Remove C5 piston 18 from C6 adapter housing module 14. 10. Remove internal sealring 20 from C5 piston 18. Remove external sealring 19 from C5 piston 18. 11. Place C6 adapter housing module 21 on press stand. Place special tool J 43047 and J 37034 onto ball bearing 26 (Figure 5–15). Support ball bearing from falling with a block of wood.

NOTE: Ball bearing assembly 26 is properly seated when it is against the shoulder at the bottom of the bearing bore and is 1.57–3.35 mm (0.062–0.132 inch) below the machined face of the adapter housing at the top of the bearing bore. 4. Press ball bearing assembly 26 into C6 adapter housing assembly 21 until it is properly seated.

J 37034

J 43047

12. Using press, remove ball bearing 26. 13. Inspect ball bearing assembly 26. Refer to Paragraph 3–5d and 3–5e. e. Assembly 1. Turn C6 adapter housing assembly 21 over and place on press stand. 2. Place ball bearing 26 in C6 adapter housing assembly 21. 3. Place special tool J 43047 and J 37034 on ball bearing assembly 26 (Figure 5–16).

V05583

Figure 5–15. Removal of Ball Bearing From C6 Adapter Housing

J 35923-4

J 37034 J 43047

V05584

V05582

Figure 5–14. Bottom View of C6 Adapter Housing and J 35923-4

5–18

Figure 5–16. Installation of Ball Bearing Into C6 Adapter Housing


MODULE REBUILD 5. Install piston ID lip-type sealring 20 onto C5 piston 18. Install external sealring 19 onto C5 piston 18. 6. Align the tang on the back of the C5 clutch piston 18 with the notch in the C6 adapter housing 22 before installing C5 clutch piston 18. Install C5 clutch piston 18 into C6 adapter housing module 14. Use a rubber mallet to seat the piston. 7. Place spring return assembly 17 in C6 adapter housing assembly 21. Use alignment notch to guide installation.

WARNING! Piston springs are highly compressed. Be extremely careful during installation. Personal injury can occur if the spring force is not controlled. 8. Place retaining ring 16 in C6 adapter housing assembly 21. 9. Compress spring and retainer assembly 17 using J 35923-4 tool base, washer, bearing, handle, and piston spring compressor J 43025. Install retaining ring 16 and slowly release the spring force (Figures 5–17 and 5–18).

f. Assembly of P4 Planetary Carrier Assembly 1. Install two caged needle bearings 42 into the center of pinion gear 41. Install thrust washers 40 in P4 planetary carrier 37. Align thrust washer tangs with slots in carrier 37 and retain them with oil-soluble grease. Slide pinion gear 41 and two bearings 42 into the side of P4 planetary carrier 37 between thrust washers 40. Repeat the procedure for the five remaining pinion gears. 2. Install six spindles 39 so the lower step is positioned for proper installation of indexing ring 35. 3. Install indexing ring 35 and internal retaining ring 34. 4. If components were replaced, measure pinion end play. Pinion end play must not exceed 0.94 mm (0.037 inch). Measure all six pinion gears. Install thrust bearing 44. 5. Install P4 planetary carrier assembly 32 into the C6 clutch drum hub 43. 6. Support P4 planetary carrier hub 43 slightly off of the work table so P4 planetary carrier assembly 32 can fall through. Install retaining ring 33 into C6 clutch hub 43

J 35923-4 J 35923

J 43025

V05582

V05581

Figure 5–17. Compressing Spring and Retainer Assembly

Figure 5–18. Bottom View of C6 Adapter Housing and J 35923-4


5–19

4000 PRODUCT FAMILY SERVICE MANUAL 7. Thread three M10 eye bolts into the P4 planetary carrier assembly 32. 8. If replacing, install P4 carrier bushing 38 in P4 carrier 37 using special tool J 43023 and J 37034 (Figure 5–19).

NOTE: • For 4700 and 4800 models with a retarder, proceed to Paragraph 5–15. • For 4700 and 4800 models without a retarder, proceed to Paragraph 5–17.

9. Install thrust bearing 31 on P4 sun gear 30. 10. With thrust bearing 31 facing up, place the thrust bearing and P4 sun gear inside P4 planetary carrier assembly 32. While holding onto P4 sun gear 30, carefully install both P4 sun gear 30 and P4 carrier assembly 32 into C6 adapter housing 22 using a sling and hoist. NOTE: Do not install ring gear and hub assembly 45 in the C6 adapter housing assembly 21 until final transmission assembly. Measurement for selective shim is performed during final buildup. g. Assembly of C6 Clutch 1. Install the C6 clutch pack in the C6 adapter housing—nine reaction plates 27 and eight friction plates 28, stacked alternately, starting with a steel reaction plate 27. Stack all plates so plate cone faces the same direction. Reaction plates 27 mesh with the C6 adapter housing 22 and friction plates 28 mesh with C6 clutch hub 43. 2. Install C6 backplate 29.

5–14. RETARDER AND P3 PLANETARY MODULE a. Disassembly of Retarder Valve Body (Foldout 10,C) 1. Remove nine bolts 93 and three bolts 89 retaining retarder control body assembly 65 to retarder housing 41 and remove control body assembly 65. 2. Remove pressure tap plug 92 and discard O-ring 91. 3. Remove separator plate 63. 4. Remove plug 81, O-ring 80, spring 78, and regulator valve 77 from retarder valve body 75. Discard O-ring 80. 5. Remove plug 83, O-ring 84, spring 85, and relay valve 86 from retarder valve body 75. Discard O-ring 84. 6. Remove retaining pin 76 from the back side of the retarder valve body 75. 7. Remove solenoid and connector assembly 71 from retarder valve body 75. 8. Remove and discard O-ring seal 73 and Oring 74. 9. Measure the resistance of retarder solenoid 72. Resistance must be 4–8 Ohms. 10. If replacement is necessary refer to the Allison 4th Generation Troubleshooting Guide, TS3989EN.

J 37034

b. Disassembly of Temperature Sensor (Foldout 10,C)

J 43023

1. Remove temperature sensor retainer bolt 48 and temperature sensor retainer 47. Carefully remove temperature sensor assembly 45 from retarder housing 41. V05587

Figure 5–19. Installation of P4 Planetary Bushing

5–20

2. Determine retarder temperature sensor resistance measured with an ohmmeter. Refer to Figure 5–20.


MODULE REBUILD 1,000,000

SENSOR RESISTANCE (‰)

100,000

10,000

1,000

100

10

1 — 40

14

68

122

— 40

—10

20

50

176

230

284

338

392

80

110

140

170

200

TEMPERATURE V04641.01

Figure 5–20. Temperature Sensor Chart

c. Disassembly of Retarder Housing (Foldout 10,C)

NOTE:

CAUTION:

Output seal 60 must be removed before retainer locknut 59 can be removed.

Be sure to remove speed sensor 53. Failure to remove the speed sensor will result in equipment damage. 1. Remove output speed sensor bolt 56, sensor retainer 55, and output speed sensor assembly 53 from the retarder housing. Remove O-ring 54 and discard. Measure output speed sensor resistance (speed sensor resistance varies by temperature). Resistance (Ohms) 250 340 450

Temperature (°C) –40 20 110

Temperature (°F) –40 68 230

5. If not removed, remove output oil seal assembly 60 using seal removal tool J 24171-A. 6. Remove bearing retaining locknut 59 using special tool J 37035. Remove Belleville washer 58.

3. Remove retaining ring 50 and valve plug 49.

7. Support retarder housing 41 so that P3 planetary carrier assembly 3 can be removed from the retarder housing. Place special tool J 37035 over the output shaft splines and against the threaded shoulder of the P3 planetary carrier. Press on J 37035 with a hydraulic press or drive on J 37035 with a mallet until the P3 planetary carrier is separated from the retarder housing.

4. Use J 42048 to compress vlave plug 33. Remove retaining ring 32 and tool J 42048. Remove valve plug 33, O-ring 34, spring 35, and retarder valve 36. Remove spring pin 37 only if damaged.

8. Remove three bolts 52 to allow removal of retarder stator assembly 18 from retarder housing 41. Remove retarder housing gasket 28.

2. Remove tachograph plug 39 and brass washer 40.


5–21

4000 PRODUCT FAMILY SERVICE MANUAL 9. Remove rotor assembly 29. Remove sealrings 27 and 30 from rotor assembly 29. Inspect splines inside rotor 29. Maximum spline wear allowed is 0.38 mm (0.015 inch). 10. If replacement is required, remove cone and roller bearing assembly 57 from retarder housing 41. If necessary to replace, remove bearing cup 51 using bearing tool J 3940. 11. Remove one bolt 99, three bolts 101, jumper manifold 98, or remote side manifold 100, and gasket 97 from rear of retarder housing 41. 12. Remove bolt 96, jumper manifold 95 or remote side manifold 97, and gasket 94 from the rear of retarder housing 41. 13. Remove nine bolts 44, cover 43, and gasket 42 from the bottom of retarder housing 41. d. Disassembly of P3 Planetary Carrier Assembly (Foldout 10,C)

WARNING! Place the P3 planetary assembly on its side to avoid possible injury while disassembling the planetary. 1. Remove retaining ring 11 and thrust washer 10 from P3 planetary carrier assembly 3. NOTE: • For 4500 models (wide ratio) transmissions, skip to Step (3). • For close ratio models, proceed with Step (2). 2. On a close ratio transmission, remove output shaft assembly 4. Inspect the splines on output shaft assembly 4. Maximum spline wear allowed is 0.38 mm (0.015 inch). 3. If replacement is necessary, remove cone and roller bearing assembly 17.

5–22

the side of P3 planetary carrier 9. Repeat the procedure with three remaining pinion gears. 7. Measure the thickness and any step wear for eight P3 thrust washers 13 and 16. Minimum allowable thickness of the thrust washers is 1.40 mm (0.055 inch). Maximum step wear allowed is 0.12 mm (0.005 inch). NOTE: • For 4500 models (wide ratio) transmissions, proceed with Step (8). • For close ratio models, skip Step (8) and proceed with Step (9). 8. On wide ratio transmissions, remove output shaft assembly 4. Inspect the splines on output shaft assembly 4. Maximum spline wear allowed is 0.38 mm (0.015 inch). 9. Inspect bushing 5 inside the end of output shaft 6 for wear or damage. Measure the ID of the output shaft bushing. Maximum allowable ID is 36.14 mm (1.423 inch). e. Disassembly of Retarder Stator Assembly (Foldout 10,C) 1. Remove O-ring 26 from retarder stator assembly 18.

WARNING! Piston springs are highly compressed. Be extremely careful during removal and installation. Personal injury can occur if the spring force is not controlled. 2. Remove C5 clutch piston 21 from retarder stator 25 by compressing spring and retainer assembly 20 using J 37030-3 tool base, washer, bearing, handle, and piston spring compressor J 37030-2. Remove retaining ring 19 and slowly release the spring force.

4. Measure pinion end play. Pinion end play must not exceed 0.94 mm (0.037 inch). Measure the three remaining pinion gears.

3. Remove C5 piston outer sealring 22 from C5 clutch piston 21.

5. Remove retaining ring 7. Remove P3 indexing ring 8. Remove four P3 planetary spindles 12.

4. Remove C5 piston inner sealring 23 from C5 clutch piston 21.

6. Slide P3 pinion gear 14, P3 thrust washers 13 and 16, and two bearing assemblies 15 from

5. If replacement is necessary, remove bearing cup 24 using bearing tool J 3940.


MODULE REBUILD 5. Install two roller bearing assemblies 15 into the center of pinion gear 14.

f. Assembly of Retarder Stator (Foldout 10,C) 1. If removed, install bearing cup 24 using bearing tool J 37033 and drive sleeve J 37034. 2. Install C5 piston inner sealring 23 onto C5 clutch piston 21. 3. Install C5 piston outer sealring 22 onto C5 clutch piston 21. 4. Align the tang notch on the back of the C5 clutch piston with the tang on retarder stator 25. Install C5 clutch piston 21 into retarder stator 25. 5. Install spring and retainer assembly 20, align the tab in the spring and retainer assembly with the notch in retarder stator 25.

WARNING! Piston springs are highly compressed. Be extremely careful during installation. Personal injury can occur if the spring force is not controlled.

6. Install thrust washers 13 and 16 in P3 planetary carrier 9, align the thrust washer tangs with the slots in the carrier, and retain them with oilsoluble grease. Slide the pinion gear and bearings into the side of the P3 planetary carrier between the thrust washers. Repeat the procedure with the three remaining pinion gears. 7. Install four planetary spindles 12 so the lower step is positioned for proper installation of indexing ring 8. 8. Install indexing ring 8. Install internal retaining ring 7. 9. If components were replaced, measure pinion end play. Pinion end play must not exceed 0.94 mm (0.037 inch). Measure all four pinion gears. h. Assembly of Retarder Housing Assembly (Foldout 10,C)

6. Compress spring and retainer assembly 20 using J 37030-3 tool base, washer, bearing, handle, and piston spring compressor J 37030-2. Install external retaining ring 19 and slowly release the spring force.

1. If removed, install bearing cup 51 using bearing tool J 37033 and drive sleeve J 37034.

7. Install O-ring 26 on retarder stator 25.

3. Install remote side manifold 100 or jumper manifold 98 and new gasket 97 to retarder housing 41 using bolt 99. Tighten bolts to 51–61 N·m (38–45 lb ft).

g. Assembly of P3 Planetary Carrier Assembly (Foldout 10,C) 1. If removed, install cone and roller bearing assembly 17. Use drive sleeve J 37034 and press the bearing against the shoulder on P3 carrier 3. 2. If removed, install bushing 5 inside the end of output shaft 6 using installer J 37036, drive handle J 8092, and a press. 3. Install output shaft assembly 4 into P3 planetary carrier 9. 4. Install thrust washer 10 and retaining ring 11 into P3 planetary carrier.

2. Install new gasket 42, cover 43, and nine bolts 44. Tighten bolts to 24–29 N·m (18– 21 lb ft).

4. Place P3 carrier assembly 3 on the work table (output shaft up) and place stator assembly 18 over the output shaft. 5. Install sealrings 27 and 30 onto rotor 29. Install the rotor assembly over the output shaft. 6. Install two M8 guide bolts into retarder stator 25. Install gasket 28 onto the guide bolts. Place retarder housing 41 over the output shaft and guide bolts, aligning the holes of the housing with the holes of the stator assembly. Remove the guide bolts as you install three bolts 52. Tighten bolts 52 to 12–15 N·m (9–11 lb ft).


5–23

4000 PRODUCT FAMILY SERVICE MANUAL 7. If removed, install cone and roller bearing assembly 57 using installer J 37034. Press cone and roller bearing assembly 57 into retarder housing 41 while rotating the retarder housing.

NOTE: Delay installing output oil seal assembly 60. 12. Install valve plug 49 and retaining ring 50.

NOTE: When installing the Belleville washer, be sure that the concave side of the washer at the inside diameter contacts the inner race of the bearing and that the anti-rotation tang engages the drilled hole in the P3 carrier. Tilt the Belleville washer, tang toward the bearing, to engage the tang into the hole. 8. Install Belleville washer 58.

CAUTION: Over-tightening bearing retainer locknut 59 will damage cone and roller bearing assemblies 17 and 57 and cups 24 and 51. 9. Lubricate output shaft threads and install locknut 59 so that the Verspel® buttons are in contact with the Belleville washer 58. Replace current locknut if it does not exhibit 3 N·m (7.5 lb ft) of running torque. 10. Using special tools J 37035 and J 43278, with the torque wrench and breaker bar positioned as shown in Figure 5–21, rotate the torque wrench clockwise to tighten bearing retainer locknut 59 to 185–200 N·m (137–147 lb ft). Locknut torque values are for bench assembly only. If the output module is mounted on the transmission, tighten the bearing retainer locknut to 74–88 N·m (55–64 lb ft). 11. Support retarder housing 41 so that the turning torque of the P3 carrier assembly 3 can be measured after installation of bearing retainer locknut 59. Use tool J 37035 to measure turning torque. Maximum turning torque is 3 N·m (27 lb inch).

5–24

13. If removed, install spring pin 37 into retarder valve 36 and insert into valve bore. Install spring 35, O-ring 34, plug 33, and retaining ring 32. Use J 42048 to compress plug 33 and install retaining ring 32. 14. Install output speed sensor assembly 53, with new O-ring 54, and output speed sensor bolt 56. Tighten the bolt to 24–29 N·m (18–21 lb ft). 15. Carefully install temperature sensor assembly 45 into retarder housing 41. Install temperature sensor retainer 47 and retainer bolt 48. Tighten the bolt to 24–29 N·m (18–21 lb ft). 16. Install brass washer 40 onto tachograph plug 39. Install plug 39 into retarder housing 41. Tighten the plug to 60–67 N·m (45–49 lb ft). i. Assembly of the Retarder Valve Body (Foldout 10,C) 1. Install new O-ring 74 and seal 73 on retarder solenoid 72. 2. Insert solenoid and connector assembly 71 into retarder valve body 75. 3. Install relay valve 86, valve spring 85, O-ring 84, and plug 83 into retarder control body 75. 4. Install regulator valve 77, valve spring 78, O-ring 80, and plug 81 into retarder control body 75. 5. Install exhaust backfill valve 70, spring 69, O-ring 68, and plug 67 into retarder control body 75.


MODULE REBUILD 6. Install guide pin 76 into the retarder control body 75. 7. Install retarder control valve cover gasket 87 and retarder control valve cover 88 on frontside and separator plate 63 on backside of retarder control valve body 75. 8. Install O-ring 91 and pressure tap plug 92. Tighten the plug to 10–13 N·m (7–10 lb ft). 9. Install retarder control body assembly 65, nine bolts 93, and three bolts 89 that retain it to retarder housing 41. Tighten bolts to 24–29 N·m (18–21 lb ft).

b. Disassembly of Temperature Sensor (Foldout 10,D) 1. Remove temperature sensor retainer bolt 38 and temperature sensor retainer 37. Carefully remove temperature sensor assembly 35 from retarder housing 31. 2. Measure retarder temperature sensor resistance measured with an ohmmeter. Refer to Figure 5–20. c. Disassembly of Retarder Housing (Foldout 10,D)

10. Skip to Paragraph 5–18.

5–15. RETARDER AND OUTPUT SHAFT MODULE (4700 and 4800 Models Equipped With Retarder) a. Disassembly of Retarder Valve Body (Foldout 10,D) 1. Remove three bolts 78 and nine bolts 82 retaining retarder control body assembly 54 to retarder housing 31 and remove control body assembly 54. 2. Remove pressure tap plug 81 and discard O-ring 80. 3. Remove separator plate 52.

CAUTION: Be sure to remove speed sensor 46. Failure to remove the speed sensor will result in equipment damage. 1. Remove output speed sensor bolt 49, sensor retainer 48, and output speed sensor assembly 46 from the retarder housing. Remove O-ring 47 and discard. Measure output speed sensor resistance (speed sensor resistance varies by temperature). Resistance (Ohms)

Temperature (°C)

Temperature (°F)

250

–40

–40

340

20

68

450

110

230

4. Remove plug 70, O-ring 69, spring 67, and valve 66 from retarder valve body 64. Discard O-ring 69. 5. Remove plug 72, O-ring 73, spring 74, and valve 75 from retarder valve body 64. Discard O-ring 73. 6. Remove retaining pin 65 from the back side of the retarder valve body 64. 7. Remove solenoid and connector assembly 60 from retarder valve body 64. 8. Remove and discard O-ring seal 62 and O-ring 63. 9. Measure the resistance of retarder solenoid 61. Resistance must be 4–8 Ohms. 10. If replacement is necessary refer to the Allison 4th Generation Troubleshooting Manual, TS3989EN.

2. Remove tachograph plug 29 and brass washer 30. 3. Remove retaining ring 40 and plug 39. 4. Use J 42048 to compress plug 23. retaining ring 22 and tool J 42048. plug 23, O-ring 24, spring 25, and valve 26. Remove spring pin 27 damaged.

Remove Remove retarder only if

NOTE: Output seal 45 must be removed before retainer locknut 44 can be removed.


5–25

4000 PRODUCT FAMILY SERVICE MANUAL 5. If not removed, remove output oil seal assembly 45 using seal removal tool J 24171-A. 6. Remove locknut 44 using special tool J 37035. Remove Belleville washer 43 (Foldout 10,D). 7. Support retarder housing 31 so that output shaft 3 can be removed from retarder housing 31. Place special tool J 37035-3 over the output shaft splines. Press on output shaft assembly 3 with a press until output shaft assembly 3 is separated from retarder housing 31. d. Completion of Retarder Housing Disassembly (Foldout 10,D) 1. Remove three bolts 20 to allow removal of retarder stator assembly 7 from retarder housing 31. Remove and discard retarder housing gasket 17. 2. Remove rotor assembly 18. Remove rotating sealrings 16 and 19 from rotor assembly 18. Inspect splines inside rotor 18. Maximum spline wear allowed is 0.38 mm (0.015 inch). 3. If replacement is required, remove cone and roller bearing assembly 42 from the retarder housing. If replacement is necessary, remove bearing cup 41 using bearing tool J 3940. 4. Remove bolt 85 and three bolts 87, jumper manifold 84 or remote side manifold 86, and gasket 83 from the rear of retarder housing 31. 5. Remove nine bolts 34, cover 33, and gasket 32 from the bottom of retarder housing 31. e. Disassembly of Output Shaft Assembly (Foldout 10,D) 1. Inspect the splines on output shaft assembly 3. Maximum spline wear allowed is 0.38 mm (0.015 inch). 2. If replacement is necessary, remove cone and roller bearing assembly 6.

5–26

3. If replacement is necessary, remove output shaft bushing 4. Maximum bushing ID allowed is 36.14 mm (1.423 in.). f. Disassembly of Retarder Stator Assembly (Foldout 10,D) 1. Remove O-ring 15 from retarder stator assembly 7.

WARNING! Piston springs are highly compressed. Be extremely careful during removal and installation. Personal injury can occur if the spring force is not controlled. 2. Remove C5 clutch piston 10 from retarder stator housing 14 by compressing piston return spring and retainer assembly 9 using J 37030-3 tool base, washer, bearing, handle, and piston spring compressor J 37030-2. Remove retaining ring 8 and slowly release the spring force. 3. Remove external sealring 11 from C5 clutch piston 10. 4. Remove internal lip-type sealring 12 from C5 clutch piston 10. 5. If replacement is necessary, remove roller bearing cup 13 using bearing tool J 3940. g. Assembly of Retarder Stator (Foldout 10,D) 1. If removed, install bearing cup 13 using bearing tool J 37033 and drive sleeve J 37034. 2. Install internal lip-type sealring 12 onto C5 clutch piston 10. Install external sealring 11 onto C5 clutch piston 10. 3. Align the tang notch on the back of the C5 clutch piston with the tang on the retarder stator before installing C5 clutch piston 10 into retarder stator 14. Install C5 clutch piston 10 into retarder stator 14.


MODULE REBUILD 4. Install spring and retainer assembly 9, aligning the tab in the spring and retainer assembly with the notch in retarder stator 14.

WARNING! Piston springs are highly compressed. Be extremely careful during installation. Personal injury can occur if the spring force is not controlled. 5. Compress piston return spring and retainer assembly 9 using J 37030-3 tool base, washer, bearing, handle, and piston spring compressor J 37030-2. Install external retaining ring 8 and slowly release the spring force.

j. Completion of Retarder Housing Assembly (Foldout 10,D) 1. If removed, install cone and roller bearing assembly 42 using installer J 37034. Press cone and roller bearing assembly 42 into retarder housing 31 while rotating retarder housing 31. NOTE: When installing the Belleville washer, make sure that the concave side of the washer at the inside diameter contacts the inner race of the bearing and that the anti-rotation tang engages the drilled hole in the P3 carrier. Tilt the Belleville washer, tang toward the bearing, to engage the tang into the hole.

6. Install O-ring 15 on retarder stator housing 14. 2. Install Belleville washer 43 (Foldout 10,D). h. Assembly of Retarder Housing (Foldout 10,D) 1. If removed, install bearing cup 41 using bearing tool J 37033 and drive sleeve J 37034. 2. Install rotating sealrings 16 and 19 onto rotor assembly 18. Install the rotor assembly 18 onto the retarder housing 31. 3. Install two M8 guide bolts into retarder stator housing 14. Install gasket 17 onto the guide bolts. Place stator assembly 7, using the guide bolts, aligning the holes of the retarder housing 31 with the holes of the stator assembly 7. Remove the guide bolts as you install three bolts 20. Tighten bolts 20 to 12–15 N·m (9–11 lb ft). i. Assembly of Output Shaft Assembly (Foldout 10,D) 1. If removed, install bushing 4 inside the end of output shaft 5 using installer J 37036, drive handle J 8092, and a press. 2. If removed, install cone and roller bearing assembly 6. Use special tools J 43202 with J 37034 and press the bearing onto output shaft 5 (Figure 5–23). 3. Support output shaft assembly 3. Place retarder housing 31 over output shaft assembly 3.

CAUTION: Over-tightening bearing retainer locknut 44 will damage roller bearings 6 and 42 and bearing cups 13 and 41. If the torque wrench and breaker bar positions in Figure 5–24 are reversed, the bearing retainer locknut will be overtorqued. Be sure wrenches are positioned ONLY as shown in Figure 5–24.

3. If using current locknut 44, lubricate the output shaft threads and install locknut 44 so that the Vespel® buttons are in contact with Belleville washer 43 (Foldout 10,D). Replace current bearing retainer locknut if it does not exhibit 5 N·m (44 lb inch) of running torque. 4. Using special tools J 37035 and J 43278, with the torque wrench and breaker bar positioned as shown in Figure 5–24, rotate the torque wrench clockwise to tighten bearing retainer locknut 44 to 185–200 N·m (137–147 lb ft). Locknut torque values are for bench assembly only. If the output module is mounted on the transmission, tighten the bearing retainer locknut to 74–88 N·m (55–64 lb ft). 5. Support retarder housing 31 so that the turning torque of the output shaft can be measured after installation of bearing retainer locknut 44


5–27

4000 PRODUCT FAMILY SERVICE MANUAL (Figure 5–24). Use tool J 43278 to measure turning torque. Maximum turning torque is 3 N·m (27 lb in.) (Figure 5–21).

NOTE: Delay installing output oil seal assembly 45 until final assembly. 6. Install plug 39 and retaining ring 40. 7. If removed, install spring pin 27 into retarder valve 26 and insert into valve bore. Install spring 25, O-ring 24, and plug 23. Use J 42048 to compress plug 23 and install retaining ring 22. 8. Install output speed sensor assembly 46, with new O-ring 47, and output speed sensor bolt 49. Tighten the bolt to 24–29 N·m (18–21 lb ft). 9. Carefully install temperature sensor assembly 35 into retarder housing 31. Install temperature sensor retainer 37 and retainer bolt 38. Tighten the bolt to 24–29 N·m (18–21 lb ft). 10. If removed, install brass washer 30 onto tachograph plug 29. Install plug 29 into retarder housing 31. Tighten plug 29 to 60–67 N·m (45–49 lb ft).

k. Assembly of the Retarder Valve Body (Foldout 10,D) 1. Install new O-ring 63 and O-ring seal 62 onto retarder solenoid 61. 2. Insert solenoid and connector assembly 60 into retarder valve body 64. 3. Install relay valve 75, valve spring 74, O-ring 73, and plug 72 into retarder control body 64. 4. Install regulator valve 66, valve spring 67, O-ring 69, and plug 70 into retarder control body 64. 5. Install exhaust backfill valve 59, spring 58, O-ring 57, and plug 56 into retarder control body 64. 6. Install guide pin 65 into the retarder control body 64. 7. Install retarder control valve cover gasket 76 and retarder control valve cover 77 on frontside and separator plate 52 on backside of retarder control valve body 64. 8. Install O-ring 80 and pressure tap plug 81. Tighten the plug to 10–13 N·m (7–10 lb ft). 9. Install retarder control body assembly 54, nine bolts 82, and three bolts 78 that retain it to retarder housing 31. Tighten bolts to 60–67 N·m (45–49 lb ft). 10. Skip to Paragraph 5–18.

5–16. REAR COVER MODULE (Models Equipped With Rear Cover, Except 4700 and 4800 Models) J 43278

a. Disassembly (Foldout 10,A) 1. Remove retaining bolt 35 and output speed sensor assembly 32. Measure output speed sensor resistance (speed sensor resistance varies by temperature). Resistance (Ohms) Temperature (°C) Temperature (°F) V05592

Figure 5–21. Output Shaft Turning Torque Measurement—Retarder Equipped

5–28

250

–40

–40

340

20

68

450

110

230


MODULE REBUILD 2. If used, remove the tachograph sensor. If present, remove plug 29 and washer or O-ring 28. 3. If not previously removed, remove output seal assembly 40 using seal removal tool J 24171-A. NOTE: Output seal 40 must be removed before retainer locknut 39 can be removed. 4. Remove bearing retainer locknut 39 using special tool J 37035.

2. On a close ratio transmission, remove output shaft assembly 6. Inspect the splines on output shaft assembly 6. Maximum spline wear allowed is 0.38 mm (0.015 inch). 3. If replacement is necessary, remove cone and roller bearing assembly 19. 4. Measure pinion end play. Pinion end play should not exceed 0.94 mm (0.037 inch). Measure the three remaining pinion gears. 5. Remove retaining ring 9. Remove indexing ring 10. Remove four planetary spindles 14.

5. Remove Belleville washer 38. 6. Support rear cover assembly 27 so that P3 planetary carrier assembly 5 can be removed. Place special tool J 37035 over output shaft splines and against the threaded shoulder of the P3 planetary carrier. Press on special tool J 37035 with a hydraulic press or drive on J 37035 with a mallet until the P3 planetary carrier assembly is separated from the rear cover assembly. 7. If replacement is required, remove cone and roller bearing 37 from rear cover assembly 27. If necessary to replace, remove bearing cup 36 using bearing tool J 3940.

6. Slide pinion gear 16, thrust washers 15 and 18, and two bearing assemblies 17 from the side of P3 planetary carrier 11. Repeat the procedure with three remaining pinion gears. 7. Measure the thickness and any step wear of eight washers 15 and 18. Minimum allowable thickness of the thrust washers is 1.40 mm (0.055 inch). Maximum step wear allowed is 0.12 mm (0.005 inch).

NOTE: b. Disassembly of P3 Planetary Carrier Assembly (Foldout 10,A)

• For 4500 models (wide ratio) transmissions,

proceed with Step (8). • For all other models, skip Step (8) and proceed

WARNING!

with Step (9).

Place the P3 planetary assembly on its side to avoid possible hand injury during disassembly. 1. Remove external retaining ring 13 and thrust washer 12 from P3 planetary carrier assembly 5. NOTE: • For 4500 (wide ratio) model transmissions, skip to Step (3). • For all other models, proceed with Step (2).

8. On 4500 model transmissions, remove output shaft assembly 6. Inspect the splines on output shaft assembly 6. Maximum spline wear allowed is 0.38 mm (0.015 inch). 9. Inspect bushing 7 inside the end of output shaft 8 for wear or damage. Measure the ID of the output shaft bushing. Maximum allowable ID is 36.14 mm (1.423 inch).


5–29

4000 PRODUCT FAMILY SERVICE MANUAL c. Completion of Rear Cover Disassembly (Foldout 10,A)

assembly with the notch in rear cover assembly 27.

WARNING!

WARNING!

Piston springs are highly compressed. Be extremely careful during removal and installation. Personal injury can occur if the spring force is not controlled.

Piston springs are highly compressed. Be extremely careful during installation. Personal injury can occur if the spring force is not controlled.

1. Remove C5 clutch piston 23 from rear cover assembly 27 by compressing spring and retainer assembly 22 using J 37030-3 tool base, washer, bearing, handle, and piston spring compressor J 37030-2. Remove retaining ring 21 and slowly release the spring force. 2. Remove piston sealring 24 from C5 clutch piston 23. 3. Remove internal sealring 25 from C5 clutch piston 23. 4. If replacement is necessary, remove bearing cup 26 using bearing tool J 3940. 5. If replacement is necessary, remove dowel pins 31. d. Beginning Rear Cover Assembly (Foldout 10,A) 1. If removed, install bearing cup 26 using bearing tool J 37033, and bearing cup 36 using bearing tool J 37033 and drive sleeve J 37034. 2. If removed, install dowel pins 31. 3. Install internal sealring 25 onto C5 clutch piston 23. Install piston sealring 24 onto C5 clutch piston 23. 4. Align the tang notch on the back of the C5 clutch piston with the tang in the rear cover before installing C5 clutch piston 23 into the rear cover. Install C5 clutch piston 23 into rear cover assembly 27. 5. Install spring and retainer assembly 22, aligning the tab in the spring and retainer 5–30

6. Compress spring and retainer assembly 22 using J 37030-3 tool base, washer, bearing, handle, and piston spring compressor J 37030-2. Install external retaining ring 21 and slowly release the spring force. e. Assembly of P3 Planetary Carrier Assembly (Foldout 10,A) 1. If removed, install cone and roller bearing assembly 19. Use driver sleeve J 37034 and press the bearing against the shoulder on the P3 carrier. 2. If removed, press bushing 7 inside the end of output shaft 8 using installer J 37036, drive handle J 8092, and a press. 3. Install output shaft assembly 6 into P3 planetary carrier 11. 4. Install thrust washer 12 and external retaining ring 13. 5. Install two roller bearing assemblies 17 into the center of pinion gear 16. Install thrust washers 15 and 18 in P3 planetary carrier 11. Align the thrust washer tangs with the slots in the carrier and retain them with oil-soluble grease. Slide pinion gear 16 and bearings into the side of the P3 planetary carrier between the thrust washers. Repeat the procedure with the three remaining pinion gears.

CAUTION: If the wear on the indexing ring is minor, flip it over to get a fresh reaction point for the spindle. Replace the indexing ring if both corners of the indexing ring are worn. Failure to take corrective action may allow the spindle to rotate which may reduce or shut off lubrication to the pinion bearings and thrust washers.


MODULE REBUILD NOTE: Replacement indexing rings should look like the example in Figure 5–12. The ring is stamped with HD5. Replacement spindles should look like the example in Figure 5–12. The spindle has a 2 stamped on the rear end. 6. Install four pinion spindles 14 so the lower step is positioned for proper installation of indexing ring 10. 7. Install indexing ring 10. Install internal retaining ring 9. 8. If components were replaced, measure pinion end play. Pinion end play must not exceed 0.94 mm (0.037 inch). Measure all four pinion gears. f. Completion of Rear Cover Assembly (Foldout 10,A)

contact with Belleville washer 38. Replace current bearing retainer locknut if it does not exhibit 5 N·m (44 lb in.) of running torque. 5. Using special tools J 37035 and J 43278, with the torque wrench and breaker bar positioned as shown in Figure 5–22, rotate the torque wrench clockwise to tighten current bearing retainer locknut 39 to 182–200 N·m (137–147 lb ft). Locknut torque values are for bench assembly only. If the output module is mounted on the transmission, tighten the bearing retainer locknut to 74–88 N·m (55–64 lb ft). 6. Support rear cover assembly 4 so that turning torque of P3 carrier assembly 5 can be measured after installation of bearing retainer locknut 39 (Figure 5–22). Use tool J 37035 to measure turning torque. Maximum turning torque is 3 N·m (27 lb in.).

1. Place P3 carrier assembly 5 on the work table (with the output shaft up) and place rear cover assembly 27 over the output shaft.

7. Install output speed sensor assembly 32, with new O-ring 33, and output speed sensor bolt 35. Tighten bolt to 60–67 N·m (45–49 lb ft).

2. If removed, install cone and roller bearing assembly 37 into rear cover assembly 27 using drive sleeve J 37034.

8. If a tachograph is used, install tachograph sensor and tighten to manufacturer’s specification. If a tachograph is used and the sensor is not installed, install brass washer 28 onto tachograph plug 29. Install plug 29 into the rear cover. Tighten plug to 60–67 N·m (45–49 lb ft).

NOTE: When installing the Belleville washer, make sure that the concave side of the washer at the inside diameter contacts the inner race of the bearing and that the anti-rotation tang engages the drilled hole in the P3 carrier. Tilt the Belleville washer, tang toward the bearing, to engage the tang into the hole.

J 37035-1

3. Install Belleville washer 38.

CAUTION: Over-tightening bearing retainer locknut 39 will damage cone and roller bearing assemblies 19 and 37 and cups 26 and 36. 4. Lubricate the output shaft threads and install locknut 39 so that the Vespel® buttons are in

V00223.00.03

Figure 5–22. P3 Carrier Turning Torque Measurement—Rear Cover Equipped


5–31

4000 PRODUCT FAMILY SERVICE MANUAL 5–17. REAR COVER AND OUTPUT SHAFT MODULE (4700 and 4800 Models Equipped With Rear Cover) a. Disassembly (Foldouts 10,B and 10,C) 1. Remove retaining bolt 23 and output speed sensor assembly 22 (Foldout 10,B). The output speed sensor must have a resistance of 270– 330 Ohms. 2. If used, remove the tachograph sensor. If present, remove plug 19 and washer 20. 3. If not previously removed, remove output seal 29 using seal removal tool J 24171-A.

NOTE: Output seal 29 must be removed before retainer locknut 28 can be removed.

4. Remove bearing retainer locknut 28 using special tool J 37035 and J 43278. 5. Remove Belleville washer 27. 6. Support rear cover assembly 17 so that output shaft assembly 6 can be removed. Press on output shaft assembly 6 until it is separated from the rear cover assembly 17 (Figure 5–23).

b. Disassembly of Output Shaft Assembly (Foldout 10,B) 1. Inspect splines on the output shaft assembly. Maximum spline wear allowed is 0.38 mm (0.015 inch). 2. If replacement is required, remove bushing 7 from output shaft 8. If replacement is needed, remove bearing 9. Maximum bushing 10 allowed is 36.14 mm (1.423 in.). c. Completion of Rear Cover Disassembly (Foldout 10,C)

WARNING! Piston springs are highly compressed. Be extremely careful during removal and installation. Personal injury can occur if the spring force is not controlled. 1. Remove C6 clutch piston 13 from rear cover 18 by compressing C5 piston spring and retainer assembly 12 using J 37030-3 tool base, washer, bearing, handle, and piston spring compressor J 37030-2. Remove retaining ring 11 and slowly release the spring force. 2. Remove external sealring 14 from C6 clutch piston 13. 3. Remove internal sealring 15 from C6 clutch piston 13. 4. If replacement is necessary, remove bearing cup 16 using bearing tool J 3940. d. Beginning Rear Cover Assembly (Foldout 10,B) 1. If removed, install bearing cup 16 using bearing tool J 37033, and bearing cup 21 using bearing tool J 37033 and drive sleeve J 37034. 2. Install internal sealring 15 onto C6 clutch piston 13. Install external sealring 14 onto C6 clutch piston 13.

V05598

Figure 5–23. Removal of Output Shaft Assembly

5–32

3. Align the tang notch on the back of the C6 clutch piston with the tang in the rear cover before installing C6 clutch piston 13 into rear cover 18. Install C6 clutch piston 13 into rear cover 18.


MODULE REBUILD 4. Install C5 piston spring and retainer assembly 12, aligning the tab in the spring and retainer assembly with the notch in rear cover 18.

J 37034

WARNING! Piston springs are highly compressed. Be extremely careful during installation. Personal injury can occur if the spring force is not controlled.

5. Compress C5 piston spring and retainer assembly 12 using J 35923-4 tool base, washer, bearing, handle, and piston spring compressor J 43025. Install retaining ring 11 and slowly release the spring force. Remove the special tools. e. Assembly of Output Shaft Assembly (Foldout 10,B) 1. If removed, install bushing 7 inside the end of output shaft 8 using installer J 37036, drive handle J 8092, and a press. 2. If removed, install cone and roller bearing assembly 9. Use special tools J 43202 with J 37034 and press the bearing onto output shaft 8 (Figure 5–24). f. Completion of Rear Cover Assembly (Foldout 10,B) 1. Support output shaft assembly 6 and place rear cover 18 over the output shaft assembly 6. 2. If removed, install cone and roller bearing assembly 27 into rear cover 18 using drive sleeve J 37034. NOTE: When installing the Belleville washer, be sure that the concave side of the washer at the inside diameter contacts the inner race of the bearing and that the anti-rotation tang engages the drilled hole in the output shaft. Tilt the Belleville washer, tang toward the bearing, to engage the tang into the hole.

J 43202

V05586

Figure 5–24. Installation of Cone and Roller Bearing Onto Output Shaft

3. Install Belleville washer 28. 4. Lubricate the output shaft threads and install locknut 28 so that the Vespel® buttons are in contact with Belleville washer 27 (Foldout 10,J). Replace current bearing retainer locknut if it does not exhibit 5 N·m (44 lb in.) of running torque.

CAUTION: Over-tightening bearing retainer locknut 29 will damage roller bearings 9 and 27 and bearing cups 16 and 21. If the torque wrench and breaker bar positions in Figure 5–25 are reversed, the bearing retainer nut will be overtorqued. Be sure wrenches are positioned ONLY as shown in Figure 5–25.

5. Using special tools J 37035 and J 43278, with the torque wrench and breaker bar positioned as shown in Figure 5–25, rotate the torque wrench clockwise to tighten current bearing retainer locknut 28 to 185–200 N·m (137–147 lb ft). Locknut torque values are for bench assembly only. If the output module is mounted on the transmission, tighten bearing retainer locknut 28 to 74–88 N·m (55–64 lb ft).


5–33

4000 PRODUCT FAMILY SERVICE MANUAL 6. Support rear cover assembly 17 so that turning torque of output shaft assembly 6 can be measured after installation of bearing retainer locknut 28. Use tool J 43278 to measure turning torque. Maximum turning torque is 3 N·m (27 lb inch) (Figure 5–25). 7. If removed, install tachograph sensor or plug 19 and washer 20.

5–18. CONTROL VALVE MODULE (Foldout 11) CAUTION: • To help prevent transmission damage protect

control module parts during removal, cleaning, inspection, and installation. Keep them in clean containers until they are installed. • Control valve module assembly springs and

NOTE: Delay installing output oil seal assembly 29.

other parts can be mistakenly interchanged. Tag each part with its item number as it is removed and use Valve Tray Set J 33163 to simplify correct valve body reassembly. • Control valve module parts fit together

8. Install output speed sensor assembly 22, with new O-ring 25, and output speed sensor bolt 23. Tighten bolt to 24–29 N·m (18–21 lb ft).

closely and have specific operating clearances. They can bind if damaged. These parts depend upon smooth sealing surfaces and may leak if the sealing surface is scratched. Valves, when dry, must move freely by their own weight in their bores. Carefully handle all such parts. NOTE: Refer to the latest revision of SIL 18-TR-98 for detailed service information regarding suspected contamination from water or Glycol. The presence of water and/or ethylene glycol coolant in the transmission fluid is detrimental to the internal components. Contaminated fluid has a deteriorating effect on transmission components.

J 43278 J 37035

a. Removal of Filters V05589.00.01

Figure 5–25. Bearing Retainer Locknut Torque—Rear Cover Equipped

5–34

1. If not previously removed, remove two filter covers 146, two gaskets 147, two O-rings 148, two O-rings 149, and two filters 150. 2. Remove three bolts 3 and face seal 6. Remove suction filter 5 and gasket 7. Discard suction filter 5 and gasket 7.


MODULE REBUILD c. Disassembly of the Solenoid Valve Body

b. Removal of Electrical Components and Sensors

1. Remove twelve bolts 57. Remove two bolts 48. NOTE: Refer to Troubleshooting Manual TS3989EN (Allison 4th Generation Controls) for inspection and repair procedures. 1. If present remove two bolts 133 and oil level sensor assembly (OLS) 134. Clean the OLS with a soft cloth. Refer to TS3989EN for sensor operation. 2. Disconnect all connectors. Release connectors in the wire harness by pushing in the center tab with a small screw driver as shown in Figure 5–26. 3. Remove three assembly 13.

bolts

46

4. Remove standoff assembly.

from

standoff

2. Remove bracket 56 with diagnostic pressure switch 55. Inspect switch for glycol contamination (refer to latest revision of SIL 18–TR-98). Maximum resistance of pressure switch 55 must not exceed 2 Ohms. Minimum resistance of pressure switch (open) must be at least 20,000 Ohms. The switch should close between 159–255 kPa (23–37 psi). 3. Remove bracket 47. 4. Remove three face seals 49. 5. Lift solenoid valve body 60 and separator plate 93 from main valve body 115 being careful not to lose the four springs 50 and 53 and accumulators 51 and 52. Set the solenoid valve body 60 on a flat work surface.

V09556.00.00

Figure 5–26. Disconnecting Connectors


5–35

4000 PRODUCT FAMILY SERVICE MANUAL 6. Remove PCS2 72 with O-rings 73 and 74. Remove valve 75 and spring 76. 7. Remove PCS1 67 with O-rings 68 and 69. Remove valve 70 and spring 71. 8. Remove TCC solenoid 62, O-rings 63 and 64, valve 65, and spring 66. 9. Insert tool J 47942 tool into slot to push in diagnostic valve 78 and release clip 77, remove spring 79 and valve 78.

WARNING! Valve springs are highly compressed. Be extremely careful during disassembly. Personal injury can occur if the spring force is not controlled. 10. Remove PCS3 80, two O-rings 81 and 82, valve 83, and spring 84. 11. Remove PCS4 85, two O-rings 86 and 87, valve 88, and spring 89. 12. Remove Main Mod solenoid 90 and two O-rings 91 and 92. 13. Measure resistance of each solenoid by using chart in Figure 5–20. d. Disassembly of C6 Control Valve Body NOTE: C6 control valve body is only in 4700 and 4800 model transmissions. 1. Remove four bolts 154 remove C6 valve body bracket 153, spring 152, accumulator 151, and valve body 156. 2. Remove pin 158 for C6 Enable solenoid 160. Remove nut 164 and plate 163, remove C6 enable solenoid 160, two O-rings 161 and 162, valve 159, and spring 157. 3. Remove screw 171 and bracket 170. Remove C6 Clutch solenoid 167, O-rings 168 and 169, valve 166, and spring 165.

5–36

4. Inspect both valves and bores for nicks, wear, and damage. e. Disassembly of Main Valve Body 1. Remove two bolts 94 and main valve body assembly 95. 2. Lift Main Control Valve body 115 and set on flat work space. 3. Remove solenoid retention pin 111 from bottom of control valve body. 4. Remove solenoid assembly 112 with O-rings 113 and 114. Measure resistance of the solenoid by using the chart in Figure 5–20. 5. Remove valve retention pin 96. 6. Remove stop 99, spring 98, and convertor flow valve 97. 7. Remove valve retention pin 100. 8. Remove stop 103, spring 102, and lube regulator valve 101.

WARNING! Valve springs are highly compressed. Be extremely careful during disassembly. Personal injury can occur if the spring force is not controlled. 9. Install spring compressor J 35924 (Figure 5–27). Compress spring 106, remove valve retention pin 104, and carefully remove compressor J 35924 after turning handle counterclockwise to release spring force. 10. Remove stop 107, spring 106, and main regulator valve 105. 11. Remove valve retention pin 111. 12. Remove clip 110, spring 109, and control main valve 108. 13. Remove valve retention pin 120. 14. Remove stop 119, spring 118, and C2 latch valve 117.


MODULE REBUILD 3. Install drain plug 141. Tighten plug to 25–32 N·m (18–24 lb ft). 4. If removed, install two pins 139. 5. Install gasket 137 and separator plate 136. h. Assembly of the Main Valve Body 1. Install converter regulator spring 130, and stop 131.

valve

129,

2. Install valve retention pin 132. 3. Install C1 latching valve 125, spring 126, and stop 127. 4. Install valve retention pin 128. Figure 5–27. Use of Tool to Release Main-Pressure Valve Spring Force

15. Remove valve retention pin 124. 16. Remove stop 123, spring 122, and exhaust back valve 121. 17. Remove valve retention pin 128. 18. Remove stop 127, spring 126, and C1 latch valve 125. 19. Remove valve retention pin 132. 20. Remove stop 131, spring 130, and converter regulator valve 129. Inspect stop 131 for battering. Replace the stop if it is battered. 21. Remove gasket 172, separator plate 136, and channel plate gasket 137. f. Disassembly of the Channel Plate 1. If damaged, remove two pins 139. 2. Remove drain plug 141 and O-ring 142. 3. Remove nine pressure tap plugs 145 with O-ring 144. 4. Remove O-rings from all tap plugs 145.

5. Install exhaust-back valve 121, spring 122, and stop 123. 6. Install valve retention pin 124. 7. Install C2 latch valve 117, spring 118, and stop 119. 8. Install valve retention pin 120. 9. Install control main valve 108, spring 109, and clip 110. 10. Install O-rings 113 and 114 on solenoid 112 and install solenoid. 11. Install solenoid retention pin 116 through bottom of main valve body assembly. 12. Install main regulator valve 105, spring 106, and stop 107. 13. Install spring compressor J 35924 (Figure 5–27). Compress spring 106, install valve retention pin 104, and remove J 35924 after turning handle counterclockwise until the tool clears pin 104. 14. Install lube regulator valve 101, spring 102, and stop 103. 15. Install valve retention pin 100. 16. Install converter flow valve 97, spring 98, and stop 99. 17. Install valve retention pin 96.

g. Assembly of the Channel Plate 1. Install new O-rings on all tap plugs 45. 2. Install nine pressure tap plugs 145. Tighten plugs to 10–13 N·m (7–10 lb ft).

18. Install main valve body assembly 95 onto seperator plate 136, channel plate gasket 137, and channel plate assembly 138. 19. Install solenoid separator plate 93 onto main valve body assembly 115.


5–37

4000 PRODUCT FAMILY SERVICE MANUAL i. Assembly of C6 Control Valve Body NOTE: Apply transmission fluid to the control module bolts as they are installed. This will provide lubrication during the installation and tightening and prevent thread seizure.

NOTE: C6 control valve body is only available in 4700 and 4800 model transmissions. 1. Install spring 157, valve 159, two O-rings 161 and 162, C6 enable solenoid 160, solenoid protective plate 163, push-on nut 164, and solenoid retention pin 158 into C6 valve body 156. 2. Install spring 165, valve 166, two O-rings 168 and 169, solenoid 167, bracket 170 and secure to C6 valve body 156 with screw 171. 3. Install accumulator plug 151 and spring 152 into C6 valve body 156. 4. Position C6 control valve body assembly 155 onto separator plate 136, channel plate assembly 137, and channel plate assembly 138. 5. Install bracket 153 and four bolts 154. Tighten the bolts to 10–13 N·m (7–10 lb ft). j. Assembly of the Solenoid Valve Body 1. Install Main Mod solenoid 90, two O-rings 91 and 92. 2. Install spring 89, valve 88, O-rings 86 and 87 and PCS4 85. 3. Install spring 84, valve 83, two O-rings 81 and and 82, and PCS3 80.

8. Install three face seals 49. 9. Install four accumulators 51 and 52 and springs 50 and 53. 10. Install bracket 47. 11. Install bracket 56 with diagnostic pressure switch 55. Inspect switch for glycol contamination, refer to the latest revision of SIL 18-TR-98. Maximum resistance of pressure switch 55 must not exceed 2 Ohms. Minimum resistance of pressure switch (open) must be at least 20,000 Ohms. The switch should close between 159–255 kPa (23–37 psi). 12. Position solenoid body assembly 59 onto solenoid separator plate 93, and control valve body 115. 13. Install twelve bolts 57. Install two bolts 48. Tighten bolts to 10–13 N·m (7–10 lb ft). k. Installation of Electrical Components and Sensors 1. Position wire harness assembly 8 onto control valve module. 2. Install wire harness assembly 8. Secure standoff assembly 13 with three bolts 46. Connect all connectors. Tighten bolts 46 to 5– 8 N·m (4–6 lb in.). 3. Postion oil level sensor assembly 134, if present onto control valve module. 4. If present install two bolts 133, two Ferrule Vitton® 135, and oil level sensor assembly 134. Tighten bolts to 10–13 N·m (7–10 lb ft). l. Install Filters

4. Install diagnostic valve 78 and spring 79. Insert tool J 47942 tool into slot to push in valve and install clip 77.

1. Install suction filter 5, gasket 7, and face seal 6. Install three bolts 3. Tighten bolts to 10–13 N·m (7–10 lb ft).

5. Install spring 66, valve 65, and TCC solenoid 62 with two O-rings 63 and 64.

2. Install case gasket 172.

6. Install spring 71, valve 70, and PCS1 67 with two O-rings 68 and 69.

5–38

7. Install spring 76, valve 75, and PCS2 72 with O-rings 73 and 74.

3. Install two filters 150, two O-rings 149 and 148, two gaskets 147, and two filter covers 146.


SECTION 6—TRANSMISSION ASSEMBLY 6–1.

SCOPE

a. Section. This section covers the assembly of 4000 Product Family transmissions. The assembly sequence is continuous and includes all models. b. Procedures. When a procedure does not apply to your specific model, go to the next applicable procedure. c. Illustrations. Illustrations will not always show your model, but when an operation is identical for all models, the correct procedure is shown. d. General Information. Refer to Section 3 for general information as follows: Paragraph

Description

3–2

Tools, Equipment

3–3

Replacement Parts

3–4

Careful Handling

3–6

Assembly Procedures

e. Foldouts. Refer to Foldouts 4 through 12 for disassembled views and torque specifications.

1. Install C3/C4 clutch assembly 1 through the input end of main housing 2, aligning the bolt holes in the clutch assembly with the holes in the main housing. 2. Install two bolts 3, 180 degrees from each other, to hold clutch assembly 1 in place. 3. Rotate the transmission housing using repair stand controls and install remaining twelve bolts 3. Tighten all bolts to 51–61 N·m (38–45 lb ft). b. Installation of Rotating Clutch Module (Figure 6–2). Use repair stand controls to put main housing in the vertical position. Use a hoist and an M16 eye bolt to insert rotating clutch module 1 in the front of the main housing.

3

1

NOTE: All parts must be cleaned and lubricated before assembly.

2

E01274.01

Figure 6–1. Main Housing and C3/C4 Clutch Installation

6–2.

ASSEMBLY OF TRANSMISSION

a. Assembly of Main Housing Module (Figure 6–1) 1

CAUTION: Before beginning assembly, attach bracket J 41445 and holding fixture J 35926 to the main housing. Use a hoist to mount the fixture and housing on repair stand J 29109.

CAUTION:

E01273.01

Be sure that main housing is horizontal when installing the C3/C4 clutch module.

Figure 6–2. Rotating Clutch Module Installation


6–1

4000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4 th GENERATION c. Installation of Front Support/Charging Pump Module (Figure 6–3)

f. Installation of C5 Clutch Pack (Figure 6–5)

1. Lower front support and charging pump module 3 over the top of the turbine shaft.

NOTE:

2. Align bolt holes in front support 3 with the threaded holes in the main housing.

The correct combination of C5 friction clutch plates and P3 ring gear must be used. Refer to SIL 12-WT-03 to determine the correct P3 ring gear and C5 friction clutch plates combination.

3. Install seven bolts 1 and seven bolts 2. Tighten bolts to 51–61 N·m (38–45 lb ft). 4. Rotate the repair stand so the rear of the main housing is facing upward. d. Installation of P1 Planetary Module (Figure 6–4) 1. Install P1 planetary module 1—consisting of the P1 carrier and P2 ring gear. 2. Mesh the P1 pinion gears with the P1 ring gear inside the C3/C4 clutch assembly.

Install the C5 clutch pack in the main housing—nine steel reaction plates 2 and eight friction plates 3, stacked alternately, starting with a steel reaction plate. Stack all plates so plate cone faces the same direction. Steel plates mesh with the main housing and reaction plates mesh with the P3 ring gear. g. Installation of Main Shaft Module (Except 4700 and 4800 Models) (Figure 6–6). Install main shaft 1 as assembled in Section 5, without selective shim 2 and thrust bearing 3

e. Installation of P2 Planetary Module (Figure 6–5) 1. Install P2 planetary module 1—consisting of the P2 carrier and the P3 ring gear. 2. Mesh the P2 pinions with the P2 ring gear during installation.

1

2 3 E01271.01

Figure 6–4. P1 Planetary Module Installation

1 1

C5

2 3

E02516.01

V01272

Figure 6–3. Front Support/Charging Pump Module Installation

6–2

Figure 6–5. P2 Planetary Module and C5 Clutch Installation


TRANSMISSION ASSEMBLY 2. Measure dimension A, from top of the straight edge to the selective shim thrust surface on the main shaft bearing spacer. 3. Measure dimension B, thickness of straight edge. Subtract dimension B from dimension A—the remainder is dimension C. 4. Place the retarder or rear cover module output end down (facing the bench top). Install an uncompressed gasket on the retarder or rear cover mounting surface and place a straight edge across the P3 planetary carrier. 5. Measure dimension D, from top of the straight edge to the gasket. 6. Measure dimension E from the top of the straightedge to the thrust bearing contact surface on the P3 planetary carrier. Subtract dimension E from dimension D—the remainder is dimension F. 7. Dimension G is the remainder of “C minus F” and determines the thickness of the selective shim. 8. Install the proper thickness selective shim and the thrust bearing.

WIDE RATIO MODELS

1

1

2

3

CLOSE RATIO MODELS

V01737.00.06

Figure 6–6. Main Shaft Module Installation

h. Installation of Main Shaft Module (4700 and 4800 Models). Install main shaft module as assembled in Section 5. i. Main Shaft Selective Shim Measurement (Close Ratio Models) (Figure 6–7) 1. Place a straight edge across the retarder or rear cover mounting surface of the main housing.

BEARING AND SHIM REMOVED

STRAIGHT EDGE

DIM. A

UNCOMPRESSED GASKET IN PLACE

STRAIGHT EDGE

DIM. E

DIM. B

DIM. C

DIM. F

DIM. D

MAIN SHAFT MODULE

RETARDER MODEL

NONRETARDER MODEL

PROCEDURE: FORMULA (C)–(F)=G DIM. G 5.7135–6.033 mm 0.231–0.237 in. 6.034–6.303 mm 0.238–0.247 in. 6.304–6.573 mm 0.248–0.258 in. 6.574–6.843 mm 0.259–0.269 in.

USE P/N

SHIM ID

29501117

1 NOTCH

29501118

2 NOTCHES

29501119

3 NOTCHES

29501120

4 NOTCHES

DIM. G 6.844–7.113 mm 0.270–0.280 in. 7.114–7.383 mm 0.281–0.290 in. 7.384–7.484 mm 0.291–0.295 in.

USE P/N

SHIM ID

29501121

5 NOTCHES

29501122

6 NOTCHES

29512774

0 NOTCHES

V03210.01.00

Figure 6–7. Main Shaft Selective Shim Measurement for 4000 Product Family—Close Ratio


6–3


1. Place a straight edge across the retarder or rear cover mounting surface of the main housing.

6. Measure dimension E from the top of the straightedge to the thrust bearing contact surface on the P3 planetary carrier. Subtract dimension E from dimension D—the remainder is dimension F.

2. Measure dimension A, from top of the straight edge to the selective shim thrust surface on the main shaft bearing spacer.

7. Dimension G is the remainder of “C minus F” and determines the thickness of the selective shim.

j. Main Shaft Selective Shim Measurement (Wide Ratio Models) (Figure 6–8)

8. Install the proper thickness selective shim and the thrust bearing.

3. Measure dimension B, thickness of straight edge. Subtract dimension B from dimension A—the remainder is dimension C.

CAUTION:

4. Place retarder or rear cover output end down (facing the bench top). Install an uncompressed gasket on the retarder or rear cover mounting surface and place a straight edge across the P3 planetary carrier.

To help prevent premature thrust bearing failure, make sure that the locating lip on either the inner or outer thrust bearing race is not preventing the race from contacting the thrust surface of the mating part. Failure to do this leads to premature thrust bearing failure and incorrect shim selection to maintain proper internal part clearance.

5. Measure dimension D, from top of the straight edge to the gasket.

BEARING AND SHIM REMOVED

STRAIGHT EDGE

DIM. A

UNCOMPRESSED GASKET IN PLACE

STRAIGHT EDGE

DIM. E

DIM. B

DIM. C

DIM. F

DIM. D

MAIN SHAFT MODULE

RETARDER MODEL

NONRETARDER MODEL

PROCEDURE: FORMULA (C)–(F)=G DIM. G 4.6177–4.843 mm 0.180–0.190 in. 4.844–5.113 mm 0.192–0.201 in. 5.114–5.383 mm 0.202–0.212 in. 5.384–5.653 mm 0.213–0.223 in.

USE P/N

SHIM ID

29503218

1 NOTCH

29503219

2 NOTCHES

29503220

3 NOTCHES

29503221

4 NOTCHES

DIM. G 5.654–5.923 mm 0.224–0.233 in. 5.924–6.193 mm 0.234–0.244 in. 6.194–6.380 mm 0.245–0.254 in.

USE P/N

SHIM ID

29503222

5 NOTCHES

29503223

6 NOTCHES

29503224

7 NOTCHES

V03211.01.00

Figure 6–8. Main Shaft Selective Shim Measurement for 4000 Product Family—Wide Ratio

6–4


TRANSMISSION ASSEMBLY k. Installation of P3 Planetary Module (4700 and 4800 Models With Retarder) (Figure 6–9) 1. Thread special tool J 43020 onto P3 Planetary Module 2 and use chain hoist to install P3 Planetary Module 2 in Main Housing Module 1. 2. Install P4 shaft flange 3. NOTE: Do not install shim locating ring or selective shim until final transmission assembly. Measurement for selective shim is performed during final buildup.

CAUTION: Over-tightening bolt 3 will damage the bolt. Use the torque formula in Figure 6–12 to find the correct torque value to apply to bolt 3. 3. Install fourteen bolts 3 through C6 adapter housing module 4 into main housing 1. Tighten bolts in a star pattern using special tool J 43046 and torque wrench to produce 100–120 N·m (74–88 lb ft) at the bolt (Figure 6–11). Use the formula in Figure 6–12 to find the correct torque wrench value that will apply to the required torque bolt 3. 1 J 43046

l. Installation of C6 Adapter Housing Module (4700 and 4800 Models With Retarder) (Figure 6–10)

2 3 4

1. Install new C6 adapter housing gasket 2.

WARNING! Get help when lifting the C6 adapter housing module. Assistance from a hoist or another person may be required. The C6 adapter housing module weighs approximately 68 kg (150 lb). 5

2. Thread two M12 bolts and attach a sling to the C6 adapter housing module 4 by positioning the housing connections equal distance from each other. Using a chain hoist, carefully lift and install the C6 adapter housing 4 onto the transmission.

V05374

Figure 6–10. Installation of C6 Adapter Housing Module

1

J 43046

2 3

4 5

J 43020 V05590

V05375

Figure 6–9. Installation of P3 Planetary Module

Figure 6–11. Tightening C6 Adapter Housing to Main Housing Bolts


6–5


BOLT (C6 adapter housing to main housing)

A TORQUE WRENCH J 43046

Tw

Ta

CLOCKWISE ROTATION

L C6 ADAPTER HOUSING

TOP VIEW L L+A L = Effective length of torque wrench A = Effective length of special tool Tw = Torque applied at the wrench (adjusted torque value to be applied with wrench) Ta = Torque applied at the bolt (ACTUAL torque value specified by service manual)

Tw = Ta X

V05591

Figure 6–12. C6 Adapter Housing to Main Housing Bolt Torque Formula

m. P3 Planetary Selective Shim Measurement (4700 and 4800 Models With Retarder) (Figure 6–13) 1. Place a straight edge across the rear face of the C6 adapter housing with uncompressed retarder housing gasket. 2. Measure dimension A, from top of the straight edge to the selective shim thrust surface on the P3 carrier face. 3. Measure dimension B, thickness of straight edge. Subtract dimension B from dimension A—the remainder is dimension C (measurement between rear face of adapter housing with uncompressed gasket and P3 carrier face).

6–6

surface. Place the P4 ring gear hub over the output shaft. Place two measuring blocks included in special tool J 43922 on the front face of retarder. Place the straight edge included in J 43922 across the top of the measuring blocks included in J 43922. 6. Measure dimension D from top of the straight edge to the face of the retarder. 7. Measure dimension E from the top of the straight edge J 43922 to the face of the P4 ring gear hub.

4. Remove retarder housing gasket.

8. Subtract dimension E from dimension D— remainder is dimension F (measurement between front face of retarder and P4 ring gear hub face)

5. Place the retarder module output end down (facing the bench top) on supports, so the output shaft is not contacting the bench

9. Dimension G is the remainder of “C minus F” and determines the thickness of the selective shim, dimension G.


4000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4 th GENERATION (measurement between rear face of adapter housing with uncompressed gasket and P3 carrier face).

n. P3 Planetary Selective Shim Measurement (4700 and 4800 Models With Rear Cover) (Figure 6–14)

4. Remove rear cover gasket.

1. Place a straight edge across the rear face of the C6 adapter housing with uncompressed rear cover gasket.

5. Place the rear cover module output end down (facing the bench top) on supports, so the output shaft is not contacting the bench surface. Place the P4 ring gear hub over the output shaft. Place the two measuring blocks included in special tool J 43922 on the front face of rear cover. Place the straight edge included in J 43922 across the top of the measuring blocks included in J 43922.

2. Measure dimension A, from top of the straight edge to the selective shim thrust surface on the P3 carrier face. 3. Measure dimension B, thickness of straight edge. Subtract dimension B from dimension A—the remainder is dimension C

DIM. B

STRAIGHT EDGE J 43922

GASKET INSTALLED STRAIGHT EDGE J 43922

DIM. A

DIM. C

MEASURING BLOCK (2), J 43922 DIM. E

DIM. F DIM. D

No Gasket

SUPPORTS

C6 ADAPTER HOUSING MODULE

RETARDER AND OUTPUT SHAFT MODULE

PROCEDURE: FORMULA C–F=G DIM. G 0.8830–1.1534 mm 0.0347–0.0454 in. 1.1535–1.4234 mm 0.0455–0.0560 in. 1.4235–1.6934 mm 0.0561–0.0666 in. 1.6935–1.9634 mm 0.0667–0.0772 in. 1.9635–2.2334 mm 0.0773–0.0879 in. 2.2335–2.5034 mm 0.0880–0.0985 in. 2.5035–2.7734 mm 0.0986–0.1091 in. 2.7735–3.0434 mm 0.1092–0.1198 in. 3.0435–3.3134 mm 0.1199–0.1304 in.

USE P/N

SHIM ID

29530516

0

29530517

1 NOTCH

29530518

2 NOTCHES

29530519

3 NOTCHES

29530520

4 NOTCHES

29530521

5 NOTCHES

29530522

6 NOTCHES

29530523

7 NOTCHES

29530524

8 NOTCHES

V05380.00.03

Figure 6–13. P3 Planetary Shim Measurement (4700 and 4800 Models With Retarder)


6–7


DIM. B

STRAIGHT EDGE J 43922

GASKET INSTALLED STRAIGHT EDGE J 43922

DIM. A

DIM. C

MEASURING BLOCK (2), J 43922 DIM. E

DIM. F DIM. D

No Gasket

SUPPORTS

C6 ADAPTER HOUSING MODULE

REAR COVER AND OUTPUT SHAFT MODULE

PROCEDURE: FORMULA C–F=G DIM. G 0.8830–1.1534 mm 0.0347–0.0454 in. 1.1535–1.4234 mm 0.0455–0.0560 in. 1.4235–1.6934 mm 0.0561–0.0666 in. 1.6935–1.9634 mm 0.0667–0.0772 in. 1.9635–2.2334 mm 0.0773–0.0879 in. 2.2335–2.5034 mm 0.0880–0.0985 in. 2.5035–2.7734 mm 0.0986–0.1091 in. 2.7735–3.0434 mm 0.1092–0.1198 in. 3.0435–3.3134 mm 0.1199–0.1304 in.

USE P/N

SHIM ID

29530516

0

29530517

1 NOTCH

29530518

2 NOTCHES

29530519

3 NOTCHES

29530520

4 NOTCHES

29530521

5 NOTCHES

29530522

6 NOTCHES

29530523

7 NOTCHES

29530524

8 NOTCHES

V05612.00.03

Figure 6–14. P3 Planetary Shim Measurement (4700 and 4800 Models With Rear Cover)

6. Measure dimension D from top of the straight edge to the face of the rear cover. 7. Measure dimension E from the top of the straight edge J 43922 to the face of the P4 ring gear hub. 8. Subtract dimension E from dimension D— remainder is dimension F (measurement between front face of rear cover and P4 ring gear hub face). 9. Dimension G is the remainder of “C minus F” and determines the thickness of the selective shim dimension G.

6–8

o. Installation of Remainder of P3 Planetary Module and C6 Adapter Housing Module (4700 and 4800 Models) (Foldout 9,C) 1. Install shim locating ring 6. 2. Install the proper selective shim 12 from previous step m or n. 3. Install retaining ring 48 into P4 ring gear 46 to complete hub assembly 45. 4. Install ring gear and hub 45.


TRANSMISSION ASSEMBLY 3. Thread an M14 eye bolt into the retarder output shaft and lift retarder module 1 onto main housing module 8. If used, install the rear support bracket.

p. Installation of Tolerance Rings Module (4700 and 4800 Models With Retarder) 1. Insert eleven tolerance rings 49 (Foldout 9,C) in counterbores flush to slightly below rear mounting surface at locations shown in Figure 6–15.

4. Install twelve bolts 2, three bolts 3, two bolts 4, four bolts 5, and four bolts 6 that secure retarder module 1 to main housing module 8. Tighten bolts 2, 4, and 5 to 100–120 N·m (74– 88 lb ft). Tighten bolts 3 and 6 to 51–61 N·m (38–45 lb ft).

q. Installation of Retarder Module (Models Equipped With Retarder, Except 4700 and 4800 Models) (Figure 6–15) 1. Install guide bolts to ease retarder module 1 installation and keep gasket 7 in place. 2. Install retarder gasket 7 over the guide bolts and against the main housing module 8.

5. Retighten bearing retainer locknut 59 (Foldout 10,E) using tool J 37035 to 74–88 N·m (55–64 lb ft).

WARNING! Get help when lifting the retarder module. Assistance from a hoist or another person may be required. The retarder module weighs approximately 34 kg (75 lb).

6. Install output shaft oil seal assembly 60, using tool J 37031.

2

2

2 2

2

2

2

2

1 2

2

2

4

8 7

4 6

3 6 5

2 5

5

5

2

5 3

4

6

6

6

3

OR

3 V06844

Figure 6–15. Retarder Module Installation


6–9

4000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4 th GENERATION r. Installation of Retarder and Output Shaft Module (4700 and 4800 Models With Retarder)

NOTE: DO NOT reuse a tang once it has been bent. Use a new locknut retainer 43 (Foldout 10,A).

1. Thread an M10 eye bolt into the output shaft assembly 3 (Foldout 10,D).

8. Install output shaft oil seal 45 (Foldout 10,A) using special tools J 43024 and J 37034, and rubber mallet (Figure 6–16).

2. Install new retarder stator housing gasket 1. 3. Install guide bolts to ease retarder and output shaft module 5 installation, and keep the gasket in place (Figure 6–17). 4. Install twelve bolts 4, two bolts 7, and four bolts 8 (Figure 6–17). Tighten bolts to 100–120 N·m (74–88 lb ft).

J 37034

J 43024

5. Install four bolts 9 and three bolts 6 (Figure 6–17). Tighten bolts to 51–61 N·m (38–45 lb ft). 6. Lift with hoist, and install retarder and output shaft module onto C6 adapter housing module 2. 7. Use special tool J 43278 and J 37035 and tighten bearing retainer locknut 39 to 74–88 N·m (55–64 lb ft) (Foldout 10,A).

V05594

Figure 6–16. Installation of Output Shaft Oil Seal (4700 and 4800 Models With Retarder)

1

4

4 2

4 4

4 3

4

4

4

4

4

4

5 7

4 7 9

8

8

9

9

9

8

6

9

4

8 6 6

OR

6

7 8 V06845

Figure 6–17. Installation of Retarder and Output Shaft Module (4700 and 4800 Models)

6–10


TRANSMISSION ASSEMBLY s. Installation of Rear Cover Module (Except 4700 and 4800 Models) (Figure 6–18) 1. Install guide bolts to ease rear cover 2 installation and keep gasket 1 in place. 2. Install a NEW rear cover gasket 1 on main housing 4. 3. Place rear cover module 2 on main housing 4 using a hoist and sling as a lifting fixture. Install rear support bracket 3 (Foldout 10,B), if used. 4. Install nineteen bolts 3 (Figure 6–18). Tighten bolts to 100–120 N·m (74–88 lb ft).

t. Installation of Rear Cover Module (4700 and 4800 Models) (Figure 6–19) 1. Install guide bolts to ease rear cover 6 installation and keep gasket 3 in place. 2. Install a NEW rear cover gasket 3 on C6 adapter housing 2. 3. Place rear cover module 6 on adapter housing 2 using a hoist and sling as a lifting fixture. Install rear support bracket, if used.

5. Retighten the spanner nut using tool J 37035 to 74–88 N·m (55–64 lb ft).

CAUTION: Do not reuse a tang once it has been bent. Install a new locknut retainer 38 (Foldout 10,A). 6. Install output shaft oil seal 5 (Figure 6–18) using tool J 37031.

4. Install fourteen bolts 4 and install five bolts 5 (Figure 6–20). Tighten bolts to 100–120 N·m (74–88 lb ft). 5. Retighten bearing retainer locknut using tool J 37035 and J 43278. Tool J 43278 holds the bearing retainer locknut while tool J 37035 turns the shaft counterclockwise to retighten the bearing retainer locknut. Tighten the locknut to 74–88 N·m (55–64 lb ft).

CAUTION: Do not reuse a tang once it has been bent. Install a new locknut retainer 28 (Foldout 10,D). 4 1

3 2

5

V06867

Figure 6–18. Rear Cover Module Installation

6. Install output shaft oil seal 29 (Foldout 10,B) using tool J 43024 and J 37034 and rubber mallet (Figure 6–22).


6–11


1 2

J 43278 J 37035

4

3

6 7

5 V05589.00.01 V05580

Figure 6–19. Installation of Rear Cover and Output Shaft Module

BOLT, M12 x 1.75 x 45 (14) MARKED 4

4

Figure 6–21. Tightening Bearing Retainer Locknut—Rear Cover Equipped

4

4

4 4

4

J 37034 4

4

J 43024 4

4

4 BOLT, METRIC HEAVY (5) MARKED 5

4 4

5

5 5

5

4

5

V05595

V07494

Figure 6–20. Rear Cover and Output Shaft Module Bolts

6–12

Figure 6–22. Installation of Output Shaft Oil Seal (4700 and 4800 Models With Rear Cover)


TRANSMISSION ASSEMBLY u. Installation of Converter Housing Module (Figure 6–23) 1. Install guide bolts to ease converter housing 1 installation and keep gasket 2 in place. 2. Position the transmission input end up. Install a NEW converter housing gasket 2 on main housing module 4. 3. Lower converter housing 1 onto main housing 4. If the transmission is PTO equipped, rotate the PTO drive gear to align the gear tangs with the charging pump. 4. Install seven bolts 3 into the inside of converter housing 1. Use mechanical fingers, or a similar tool, when installing these bolts. 5. Remove the two guide bolts and install the remaining bolts 3. Tighten all bolts 3 to 51–61 N·m (38–45 lb ft).

v. Installation of Torque Converter Module (Figure 6–24) 1. The torque converter is installed over the turbine shaft which rotates inside the stator shaft or ground sleeve. The splines on the ground sleeve engage the converter stator. The splines on the turbine shaft engage the converter turbine. The end of the turbine shaft is threaded and machined to accept the converter retaining bolt and lockup sealring. 2. The splines of the ground sleeve and turbine shaft must engage with their respective splines in the torque converter module. The tangs on the converter-pump hub must engage the charging pump’s drive gear or the PTO oil pump drive hub. 3. Using a hoist and sling, install torque converter module 6 into the converter housing module (Figure 6–24, View A). 4. Make sure that the torque converter is properly seated. If PTO equipped, rotate the PTO gear to engage the pump hub with the charging pump. Proceed with the selective shim measurement. 5. Install converter end play gauge J 38548 and tighten the attaching bolt to 27–34 N·m (20–25 lb ft). Prevent turbine shaft rotation by using one of the following methods: • Insert a screwdriver into the vanes on the

1

rotating clutch module (Figure 6–24, View B).

3

• If the control module is in place, apply air 2

4

V06868

Figure 6–23. Converter Housing Module Installation

pressure through the lockup pressure tap and use a heel bar, screwdriver, and bolts. Insert the heel bar into a torque converter housing bolt hole. Insert two bolts into the flexplate adapter bolt holes. Then place a screwdriver at an angle to prevent converter rotation (Figure 6–24, View C).


6–13


CUPPED END DOWN

2

5 1

3

RESTRICT MOVEMENT USE HOIST AND SLING

4

J 38564

VIEW A

VIEW B

VIEW C

VIEW D

Figure 6–24. Torque Converter Module Installation and Selective Shim Measurement

6–14


VL06869.01.00

TRANSMISSION ASSEMBLY NOTE: Dimension C shown in Table 6–1 includes a correction due to internal deflection caused by the 27–34 N·m (20–25 lb ft) bolt torque applied to gauge J 38548. Correct torque value is critical to selection of the proper shim. 6. Measure from top of tool J 38548 to face of turbine shaft and record it as dimension B (Figure 6–24, View D). Subtract dimension B from dimension A to determine dimension C. (Dimension A is the height of tool J 38548, 100.00 mm; 3.937 inch.)

7. Use dimension C and Table 6–1 to determine proper selective shim part number. Remove tool J 38548 and continue with installation of the torque converter. 8. Keep the torque converter cover from turning by using a heel bar, two bolts, and a screwdriver (Figure 6–24, View C). 9. Install threaded plug 7 and O-ring 8 using a 3⁄4 inch Allen socket. Tighten plug to 50–60 N·m (37–44 lb ft). 10. Install converter shipping brackets 1 (Foldout 12,B), or equivalent, to prevent torque converter movement. Tighten the shipping bracket bolts to 51–61 N·m (38–45 lb ft).

Table 6–1. Torque Converter Selective Shims Dimension C

Use P/N

Shim Thickness (Ref.)

ID No.

0.4129–0.6598 mm (0.0163–0.0259 inch)

29505688

4.000 mm (0.157 inch)

0

0.6599–0.8378 mm (0.0260–0.0329 inch)

29505681

4.203 mm (0.165 inch)

1

0.8379–1.0158 mm (0.0330–0.0399 inch)

29505682

4.381 mm (0.172 inch)

2

1.0159–1.1938 mm (0.0400–0.0469 inch)

29505683

4.559 mm (0.179 inch)

3

1.1939–1.3708 mm (0.0470–0.0539 inch)

29505684

4.736 mm (0.186 inch)

4

1.3709–1.5488 mm (0.0540–0.0609 inch)

29505685

4.914 mm (0.193 inch)

5

1.5489–1.7268 mm (0.0610–0.0679 inch)

29505686

5.092 mm (0.200 inch)

6

1.7269–1.9048 mm (0.0680–0.0749 inch)

29507793

5.270 mm (0.207 inch)

7

1.9049–1.9733 mm (0.0750–0.0776 inch)

29507794

5.448 mm (0.214 inch)

8


6–15

4000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4 th GENERATION w. Installation of Control Module (Figure 6–25)

NOTE: Apply transmission fluid to the control module bolts as they are installed. This will provide lubrication during the installation and tightening and prevent thread seizure.

1. Place the transmission in a vertical position, front end upward. 2

2. Install two guide pins in two main housing bolt holes.

WARNING! Get help when lifting the control module. Assistance from another person may be required. The control module weighs approximately 25 kg (55 lb).

1

3. Lubricate the feedthrough hole in the main housing with oil-soluble grease.

3

4 V09785.00.00

4. Guide control module 1 onto the main housing and pass feedthrough harness connector through the feedthrough hole in the main housing. 5. Align the control module bolt holes with the guide pins. Make sure the feedthrough harness standoff is aligned with the feedthrough hole in the main housing.

Figure 6–25. Control Module Installation

x. Installing Integral Oil Cooler (Figure 6–26) 1. Install nine washers 6 on nine M10 x 1.5 x 70 bolts 7. 2. Install two bolts 7 into the upper corners of cooler housing 3. 3. Install gasket 1 over bolts 7.

6. Lower the control module over the guide pins until it seats against the main housing. 7. Install filter cover assemblies prepared in Paragraph 5–18.

6–16

4. Position cooler housing transmission main housing.

3

against

the

5. Tighten two bolts 7 finger tight, making sure gasket 1 is properly positioned.


TRANSMISSION ASSEMBLY 6. Install the remaining seven bolts 7 into cooler housing 3. Tighten nine bolts 7 to 51–61 N·m (38–45 lb ft).

4. Install cooler manifold 16 over the headless guide bolts. 5. Install three M12 x 1.75 x 195 bolts 10. Tighten bolts to 100–120 N·m (74–88 lb ft).

7. Install two O-rings 8 onto plate assembly 9. 8. Install plate assembly 9 into cooler housing 3 so that O-rings 8 seal against the transmission main housing.

6. Remove the two headless guide bolts.

9. Install two bolts 12 into the upper corners of cover 13.

8. Install M10 x 1.5 x 50 bolt 8. Tighten bolt to 51–61 N·m (38–45 lb ft).

7. Install seven M10 x 1.5 x 187.5 bolts 9. Tighten bolts to 51–61 N·m (38–45 lb ft).

9. Rotate the transmission so that the breather is facing up.

10. Install gasket 14 over bolts 12. 11. Install cover 13 onto cooler housing 3. Tighten two bolts 12 finger tight. 12. Install the fifteen remaining bolts 12. Tighten bolts 12 to 51–61 N·m (38–45 lb ft). 13. Install two bolts 11. Tighten two bolts 11 to 100–120 N·m (74–88 lb ft). y. Installing Integral Retarder Sump Oil Cooler (Foldout 12,C) 1. Rotate the transmission so that the retarder is facing up. 2. Install two headless guide bolts into the retarder housing. 3. Install gasket 4 over the headless guide bolts.

10. Install two headless guide bolts into each manifold to cooler mating surface. 11. Install gaskets 6 over the headless guide bolts.

WARNING! To help avoid personal injury, securely support the cooler in its installed position before installing the bolts retaining the cooler to the manifold. The cooler weighs 30 kg (64 lb); use care when handling the cooler. 12. Install cooler 7 over the headless guide bolts and install two M10 x 1.5 x 60 bolts 1 so that the cooler is retained to the cooler manifold. Do not install bolts into the inlet or outlet hose adapter bolt holes. Tighten bolts finger tight. 4

5

3 1 11 4 5

8 2 6 7 8 19 18 17 19 18 17

11

15

9 10

10

16

11 12 14 13

11

V06843

Figure 6–26. Integral Oil Cooler Installation


6–17

4000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4 th GENERATION 20. If used, install the retarder accumulator hose onto the fitting on cooler manifold 16.

13. Remove the two headless guide bolts. 14. Install two gaskets 3.

z. Installation of Externally Mounted Parts (Figure 6–27)

15. Align and install two inlet or outlet hose adapters 2.

1. If not previously installed, install transmission breather 20. Tighten breather to 12–16 N·m (9–12 lb ft).

16. Install the remaining fourteen M10 x 1.5 x 60 bolts 1. 17. Evenly tighten sixteen M10 x 1.5 x 60 bolts 1 to 51–61 N·m (38–45 lb ft).

2. Install fill tube seal 9, fill tube 8, bracket 6, and screw 5. Tighten screw to 24–29 N·m (18–21 lb ft). Install dipstick 7.

18. Install six bolts 5. Tighten bolts to 24–29 N·m (18–21 lb ft).

3. If used, install new cooler port gasket 10. Install remote mount manifold 11 and six bolts 12. Tighten bolts to 51–61 N·m (38–45 lb ft).

19. Install water inlet and outlet hoses.

20

ENGINE SPEED SENSOR

2 TURBINE 1 SPEED SENSOR

3

4

7 5

6

8

9 OUTPUT SPEED SENSOR

15

13 16 10 11

17

18

19

12 14

V06837.03.00

Figure 6–27. Installation of Externally Mounted Parts

6–18


TRANSMISSION ASSEMBLY ab. Removal of Transmission From Repair Stand

4. If removed, use special tool J 46150 to press a new slinger 13 onto the flange or yoke.

WARNING!

5. Install output flange 15 or yoke 14.

Dry weight of 4000 Product Family transmissions with PTO provision and retarder is 439 kg (968 lb); with PTO provision is 405 kg (893 lb). The dry weight of 4700 and 4800 models with PTO provision and retarder is 555 kg (1224 lb), dry weight of 4700 and 4800 models with PTO provision is 521 kg (1149 lb).

6. Install O-rings 16 on plug 18. 7. Insert bolt 19 into plug 18. 8. Install O-ring 17 over the threaded end of bolt 19, so that the O-ring seats against the retainer plug. 9. Install retainer plug 18 into the yoke or flange. Tighten bolt 19 to 70–80 N·m (51–60 lb ft).

Using hoist, remove transmission and holding fixture from repair stand and prepare for vehicle installation.

aa. Installation of Power Takeoff (Figure 6–28) 1. If removed, install two PTO pilot screws 4.

NOTE:

2. Install PTO gasket 3 and PTO assembly 2. Insert one bolt 1 into each of the 6 o’clock and 12 o’clock positions. Install the remaining six bolts. Tighten bolts to 51–61 N·m (38–45 lb ft).

Refer to Mechanic’s Tips MT4015EN for preparing transmission for installation and installing the transmission into a vehicle.

1

2 4 3

3

1 2

4 V06836

Figure 6–28. PTO Installation


6–19


6–20


SECTION 7—WEAR LIMITS AND SPRING DATA 7–1.

WEAR LIMITS DATA

which do not meet the load height specifications according to Table 7–2, Spring Data.

a. Maximum Variations. Wear limit information in this Section shows the maximum wear at which components are expected to function satisfactorily. Table 7–1 lists the Wear Limits Data and is referenced to the exploded views (Foldouts 4 through 12) in the back of this manual.

b. Inspection. Inspection criteria (load vs. height) and identification characteristics of the springs are presented in Table 7–2. The Spring Data are keyed to the exploded views (Foldouts 4 through 12) in the back of this manual.

b. Cleaning And Inspection. Parts must be clean to permit effective inspection for wear or damage. Refer to Section 3.

NOTE:

7–2.

SPRING DATA

a. Spring Replacement. Springs should be replaced if there are signs of overheating, wear due to rubbing adjacent parts, or permanent set. Discard springs

When more than one spring part number is listed for the same location, refer to the 4000 Product Family Parts Catalog PC2456EN to determine which spring is used in your specific assembly number.

Table 7–1. Wear Limits Data Wear Limit Illustration

Description

Foldout 4,B

TORQUE CONVERTER MODULE

mm

(inches)

66.91

2.634

10

Converter Cover Bushing, Maximum ID

12

Lockup Piston Assembly, Minimum Thickness

6.53

0.257

14

Damper Assembly Plate, Maximum Distortion

0.51

0.020

14

Damper Assembly Plate, Minimum Thickness

8.51

0.335

Turbine-To-Damper, Maximum Spline Wear

0.38

0.015

15

Backplate, Maximum Distortion

0.15

0.006

15

Backplate, Minimum Wear Surface Thickness

11.79

0.464

18

Turbine Hub, Minimum OD

66.69

2.626

19

Turbine Hub Sealring, Maximum ID

61.77

2.432

24

Stator Thrust Plate, Minimum Thickness

9.45

0.372

36

Converter Pump Hub, Minimum OD

88.99

3.504

89.19

3.511

14, 18

Foldout 5,B 6

TORQUE CONVERTER HOUSING MODULE—PTO EQUIPPED Bearing Retainer Bushing, Maximum ID

8, 14

Oil Pump Drive Hub Seal, Minimum End Gap

1.18

0.047

8, 14

Oil Pump Drive Hub Seal, Maximum End Gap

1.66

0.065

Oil Pump Drive Hub, Maximum Tang Wear

0.31

0.012

13


7–1

4000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4 th GENERATION Table 7–1. Wear Limits Data (cont’d) Wear Limit Illustration

Description

mm

(inches)

Foldout 6,A

FRONT SUPPORT AND CHARGING PUMP MODULE Pump Housing Bushing, Maximum ID

89.19

3.511

9, 10

Pump Housing Gear, Maximum Cavity Depth

19.04

0.750

9, 10

Pump Housing Gear, Maximum Cavity Diameter

150.25

5.915

8

9, 10, 11

Driven Gear-To-Pump Housing, Maximum Diametric Clearance

0.30

0.012

9, 10, 13

Gear-To-Plate, Maximum Side Clearance

0.10

0.004

11

Gear Set, Maximum Gear Tooth Tip Clearance

0.15

0.006

12

Pump Gear Bushing, Maximum ID

66.93

2.635

Ground Sleeve, Minimum OD In Bushing Area

66.67

2.625

0.13

0.005

119.81

4.717

16, 17 16, 17, 20 20

Front Support, Minimum OD

25

Front Support Seal, Minimum End Gap

1.00

0.040

25

Front Support Seal, Maximum End Gap

1.44

0.056

36.14

1.423

Foldout 6,B

ROTATING CLUTCH MODULE

5

Turbine Shaft Bushing, Maximum ID

8

Turbine Seal, Minimum End Gap

0.65

0.026

8

Turbine Seal, Maximum End Gap

1.01

0.039

9

Drum Spline, Maximum Wear

0.38

0.015

12

Rotating Clutch Hub Bushing, Maximum ID

120.27

4.735

29

C1 Clutch Apply Plate, Minimum Thickness

5.90

0.232

29, 39

C1 Clutch Apply Plate or C2 Backplate, Maximum Distortion

0.15

0.006

30, 38

C1, C2 Friction Plate, Maximum Cone

0.25

0.010

30, 38

C1, C2 Friction Plate, Minimum Thickness

2.92

0.115

30, 38

C1, C2 Friction Plate, Minimum Oil Groove Depth

0.20

0.008

31, 37

C1, C2 Reaction Steel Plate, Maximum Cone

0.25

0.010

31, 37

C1, C2 Reaction Steel Plate, Minimum Thickness

2.41

0.095

32

C1 Clutch Backplate, Minimum Thickness @ ID

9.90

0.390

C1, C2 Drive Hub, Maximum Spline Wear

0.38

0.015

C2 Backplate, Minimum Thickness

7.90

0.311

34, 36 39

7–2

Spline OD, Maximum Total Runout


WEAR LIMITS AND SPRING DATA Table 7–1. Wear Limits Data (cont’d) Wear Limit Illustration Foldout 7

Description

mm

(inches)

MAIN HOUSING MODULE

4

Backplate, Maximum Step Wear

0.13

0.005

4

Backplate, Maximum Distortion

0.15

0.006

P1 Ring Thrust Plate, Minimum Thickness At Wear Point

2.82

0.111

P1 Ring Gear Spline, Maximum Wear

0.38

0.015

8, 21, 29

C3, C4, C5 Friction Plate, Maximum Cone

0.25

0.010

8, 21, 29

C3, C4, C5 Friction Plate, Minimum Thickness

3.485

0.137

C3, C4 Friction Plate, Maximum Friction Material Erosion Around Lubrication Slots

4.00

0.157

9, 20, 30

C3, C4, C5 Reaction (Steel) Plate, Maximum Cone

0.25

0.010

9, 20, 30

C3, C4, C5 Reaction (Steel) Plate, Minimum Thickness

3.25

0.128

11, 23

C3, C4 Piston Return Plate, Minimum Thickness

4.91

0.193

19, 28

C3, C4 Clutch Housings, Maximum Spline Wear

1.15

0.045

Main Housing, Maximum Spline Wear

1.15

0.045

5, 18 7

8, 21

43 Foldout 8

MAIN SHAFT MODULE—WIDE RATIO AND CLOSE RATIO

7, 8

Main Shaft Bearing Journal, Minimum OD

52.98

2.085

7, 8

Main Shaft Pilots (both ends), Minimum OD

35.92

1.414

7, 8

Main Shaft Spines, Maximum Wear

0.38

0.015

0.94

0.037

89.32

3.516

Foldout 9,A

P1 PLANETARY MODULE

3

P1 Planetary Carrier Assembly, Maximum Pinion End Play

9

P1 Carrier Bushing, Maximum ID

10, 13

P1 Pinion Thrust Washer, Minimum Thickness

1.40

0.055

10, 13

P1 Pinion Thrust Washer, Maximum Step Wear

0.12

0.005


0.38

0.015

0.94

0.037

53.23

2.096

15 Foldout 9,B

P2 PLANETARY MODULE

1


8


9, 12


1.40

0.055

9, 12


0.12

0.005


0.38

0.015

15


7–3

4000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4 th GENERATION Table 7–1. Wear Limits Data (cont’d) Wear Limit Illustration

Description

Foldout 9,C

P3 PLANETARY AND C6 ADAPTER HOUSING MODULE (4700 and 4800 models)

(inches)

1

P3 Carrier Module, Maximum Pinion End Play

0.94

0.037

8


1.40

0.055

8


0.12

0.005

27

C6 Reaction Plate, Minimum Thickness

3.24

0.128

C6 Friction and Reaction Plate, Maximum cone

0.25

0.010

28

C6 Friction Plate, Minimum Thickness

3.68

0.145

32

P4 Carrier Assembly, Maximum Pinion End Play

0.94

0.037

38


113.33

4.462

40

P4 Planetary Thrust Washer, Minimum Thickness

1.40

0.055

40

P4 Planetary Thrust Washer, Maximum Step Wear

0.12

0.005

0.94

0.037

27, 28

Foldout 10,A

REAR COVER AND P3 MODULE (except 4700 and 4800 models)

5

P3 Planetary Carrier Assembly, Maximum End Play

7

Output Shaft Bushing, Maximum ID

36.14

1.423

8

Output Shaft, Maximum Spline Wear

0.38

0.015

15, 18


1.40

0.055

15, 18


0.12

0.005

Foldout 10,B

REAR COVER AND OUTPUT SHAFT MODULE (47000 and 4800 models)

7


36.14

1.423

8


0.38

0.015

0.94

0.037

36.14

1.423

Foldout 10,C

RETARDER AND P3 MODULE (except 4700 and 4800 models)

3


5


13, 16


1.40

0.055

13, 16


0.12

0.005

27, 30

Retarder Rotor Sealring, Maximum ID

139.72

5.501

0.38

0.015

29

7–4

mm

Rotor Hub, Maximum Spline Wear


WEAR LIMITS AND SPRING DATA Table 7–1. Wear Limits Data (cont’d) Wear Limit Illustration

Description

Foldout 10,D

RETARDER AND OUTPUT SHAFT MODULE (4700 and 4800 models)

mm

(inches)

4


36.14

1.423

5


0.38

0.015

139.72

5.501

0.38

0.015

85.0

3.346

16, 19 18 Foldout 12,A 1, 4, 5, 6, 9, 10, 11, 12

Retarder Rotor Sealring, Maximum ID Rotor Hub, Maximum Spline Wear OUTPUT FLANGE AND YOKE Output Seal Journal, Minimum OD


7–5

7–6

Ref.

26

22

20

25

25

10

22

17

22

12

20

9

35

25

70

Foldout

4,B

6,A

6,B

6,B

6,B

7

7

9,C

10,A

10,B


10,C

10,D

10,C

10,D

10,C

Exhaust Backfill

Retarder Flow Valve

Retarder Flow Valve

C5 Return

C5 Return

C5 Return

C5 Return

C5 Return

C4 Return

C3 Return

C1 Return

C1 Return

C2 Return

Main Relief

Stator

Spring

23049391 No Code

29515692 No Code

29515692 No Code

29503036 No Code

29503036 No Code

29503036 No Code

29503036 No Code

29530488 No Code

29542504 Pink

29542504 Pink

29537301 No Code

29509453 No Code

29505719 No Code

29507709 No Code

29501300 No Code

Part No.

Color Code

20.40

11.4

11.4

12*

12*

12*

12*

11.6*

13.8

13.8

11.8*

12*

11.5*

10

N/A

No. of Coils N/A 17.96 (0.707) 19.06* (0.750) 16.0* (0.630) 16.8* (0.661) 15.0* (0.590) 15.0* (0.590) 17.00* (0.669) 17.00* 17.00* 17.00* 17.00* 36.17 (1.424) 36.17 (1.424) 8.00 (0.315)

3.25 (0.128) 2.04* (0.080) 2.10* (0.083) 2.17* (0.085) 2.10* (0.083) 2.10* (0.083) 2.03* (0.080) 2.10* (0.083) 2.10* (0.083) 2.10* (0.083) 2.10* (0.083) 4.12 (0.162) 4.12 (0.162) 0.61 (0.024)

Spring OD mm (in.)

N/A

Wire Dia mm (in.)

Table 7–2. Spring Data

29.2 (1.15)

114.3 (4.500)

114.3 (4.500)

57.3* (2.26)

57.3* (2.26)

57.3* (2.26)

57.3* (2.26)

53.80 (2.11)

55.55* (2.187)

55.55* (2.187)

52.89* (2.082)

57.53* (2.265)

70.76* (2.786)

18.2 (0.716)

91.1 (3.587)

91.1 (3.587)

37.6 (1.48)

37.6 (1.48)

37.6 (1.48)

37.6 (1.48)

37.7 (1.48)

39.25 (1.545)

39.25 (1.545)

34.5 (1.358)

34.8 (1.37)

28.2 (1.110)

40.7 (1.60)

5.7 (0.224)

17.8 (0.70) 52.4 (2.06)

mm (in.)

2.67 (0.60)

213.3 (47.95)

213.3 (47.95)

3086** (693.8)

3086** (693.8)

3086** (693.8)

3086** (693.8)

3611** (811.8)

143.5** (32.3)

143.5** (32.3)

4893** (1100.0)

4649** (1045.4)

5185** (1165.6)

474 (106.5)

0.9 (0.2)

N (lb)

Length under load

Approx. Free Length mm (in.)


Ref.

59

78

67

85

74

50

130

123

175

180

100

112

134

Foldout

10,D

10C

10D

10C

10D

11

11

11

11

11


11

11

11

Converter Regulator

Control Main

Connector Flow

C6 Clutch

C6 Enable

C2 Latch

C1 Latch

Accumulator

Relay Valve

Relay Valve

Regulator Valve

Regulator Valve

Exhaust Backfill

Spring

12.19 (0.480) 7.43 (0.293) 16.26 (0.640) 11.43 (0.450) 10.75 (0.423) 11.05† (0.435) 14.10 (0.555) 14.8 (0.583) 11.00 (0.433)

0.97 (0.038) 0.97 (0.038) 0.97 (0.038) 0.97 (0.038) 0.94 (0.037) 1.37 (0.054) 1.32 (0.052) 1.22 (0.048) 0.67 (0.026) 1.37 (0.054) 1.83 (0.072) 1.53 (0.060)

Lt. Green/ 10.45 Silver Lt. Green/ 10.45 Silver Lt. Green/ 10.45 Silver Lt. Green/ 10.45 Silver Dk. Green 15.90 Dk. Blue

29507456 Pink

29542926 Orange

23049326 No Code

29542936 No code

29542949 No code

29542929 Lt. Green

29542929 Blue

8678805

29529310

29529310

29529310

29529310

10.20

10

10

4

6.90

11

12

12.19 (0.480)

12.19 (0.480)

12.19 (0.480)

8.00 (0.315)

0.61 (0.024)

20.40

23049391 No Code

Part No.

No. of Coils

Spring OD mm (in.)

Color Code

Wire Dia mm (in.)

Table 7–2. Spring Data (cont’d)

30.3 (1.19)

44.6 (1.76)

42.1 (1.66)

6.5 (0.26)

16.71 (0.658)

41.3 (1.63)

46.2 (1.82)

30.82 (1.213)

38.15 (1.502)

38.15 (1.502)

38.15 (1.502)

38.15 (1.502)

29.2 (1.15)


22.8 (0.90)

24.2 (0.95)

17.0 (0.67)

3.45 (0.14)

12.84 (0.506)

19.0 (0.75)

29.2 (1.15)

18.20 (0.717)

17.70 (0.697)

17.70 (0.697)

17.70 (0.697)

17.70 (0.697)

18.2 (0.716)

mm (in.)

53.7–59.3 (12.1–13.3)

131–145 (29.5–32.6)

49.2–60.2 (11.06–13.53)

3.2–4.2 (0.72–0.94)

18.14–21.86 (4.08–4.91)

64.1–78.3 (14.4–17.6)

16.7–18.9 (3.75–4.25)

27.59 (6.20)

14.70 (3.31)

14.70 (3.31)

14.70 (3.31)

14.70 (3.31)

2.67 (0.60)

N (lb)

Length under load

WEAR LIMITS AND SPRING DATA

7–7

7–8

79

104

108

71

76

84

89

66

11

11

11

11

11

11

11

11

TCC

PCS4

PCS3

PCS2

PCS1

Main Regulator

Lube Regulator

Diagnostic

Spring

* Individual Springs ** For the complete Spring Assembly † OD at larger end

Ref.

Foldout

29542938 No Code

29542936 No Code

29542936 No Code

29542936 No Code

29542936 No code

29500963 Lt. Blue

23049327 Red

29542941 No Code

Part No.

Color Code

4

4

4

4

4

15

13

9

No. of Coils

Spring OD mm (in.) 10.50 (0.433) 11.10 (0.437) 22.0 (0.866) 11.05† (0.435) 11.05† (0.435) 11.05† (0.435) 11.05† (0.435) 11.05† (0.435)

Wire Dia mm (in.) 1.30 (0.039) 1.22 (0.048) 2.87 (0.113) 0.67 (0.026) 0.67 (0.026) 0.67 (0.026) 0.67 (0.026) 0.67 (0.026)

Table 7–2. Spring Data (cont’d)

6.5 (0.26)

6.5 (0.26)

6.5 (0.26)

6.5 (0.26)

6.5 (0.26)

98.5 (3.88)

46.3 (1.82)

27.03 (1.06)


3.45 (0.14)

3.45 (0.14)

3.45 (0.14)

3.45 (0.14)

3.45 (0.14)

54.6 (2.15)

23.5 (0.93)

15.49 (1.02)

mm (in.)

3.2–4.2 (0.72–0.94)

3.2–4.2 (0.72–0.94)

3.2–4.2 (0.72–0.94)

3.2–4.2 (0.72–0.94)

3.2–4.2 (0.72–0.94)

305–337 (68.6–75.8)

46.5–51.3 (10.5–11.5)

2.45 (0.78)

N (lb)

Length under load



SECTION 8—CUSTOMER SERVICE 8–1.

OWNER ASSISTANCE

The satisfaction and goodwill of the owners of Allison transmissions are of primary concern to Allison Transmission, 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: • Expert service by trained personnel • Emergency service 24 hours a day in many areas • Complete parts support • Sales teams to help determine your transmission 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 or utilize Allison Transmission’s Sales and Service Locator tool on the Allison Transmission web site at www.allisontransmission.com. You may also refer to Allison Transmission’s Worldwide Sales and Service Directory (SA2229EN). 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 your 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 Allison Transmission dealers are associated with an Allison Transmission 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 Allison Transmission distributor’s name, address, and telephone number on request.

Step Two—When it appears the problem cannot be readily resolved at the distributor level without additional assistance, contact the Allison Technical Assistance Center at 800-252-5283. They will place you in contact with the Regional Customer Support Manager for your area. For prompt assistance, please have the following information available. • Name and location of authorized distributor or

dealer • Type and make of vehicle/equipment • Transmission model number, serial number,

and assembly number (if equipped with electronic controls, also provide the TCM assembly number) • Transmission delivery date and accumulated

miles and/or hours of operation • Nature of problem • Chronological summary of your transmission’s

history Step Three—If you are still not satisfied after contacting the Regional Customer Support Manager, present the entire matter to the Home Office by writing to the following address: Allison Transmission Manager, Warranty Administration P.O. Box 894, Mail Code 462-470-PF9 Indianapolis, IN 46206-0894 The inclusion of all pertinent information will assist the Home Office in expediting the matter. When contacting the 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 that Step 1 be followed when experiencing a problem. Your purchase of an Allison Transmission product is greatly appreciated, and it is our sincere desire to assure complete satisfaction.


8–1


SERVICE LITERATURE (Table 8–1)

Additional service literature is available. This service literature provides fully illustrated instructions for operation, maintenance, service, overhaul, and parts support for your transmission. To be sure that you get maximum performance and service life from your transmission, you may order publications from: SGI, Inc. Attn: Allison Literature Fulfillment Desk 8350 Allison Avenue Indianapolis, IN 46268 TOLL FREE: 888-666-5799 INTERNATIONAL: 317-471-4995

Table 8–1. 4000 Product Family Service Literature Publication Type Allison DOC™ For PC–Service Tool User Guide Automatic Transmission Fluid Technician’s Guide *Operator’s Manual (Bus Series) *Operator’s Manual (Emergency Vehicle Series) *Operator’s Manual (Highway Series) *Operator’s Manual (International Models) *Operator’s Manual (Motorhome Series) *Operator’s Manual (Rugged Duty Series) *Operator’s Manual (Specialty Series) *Operator’s Manual (Truck Recreational Vehicle Series) *Mechanic’s Tips *Mechanic’s Tips (T Series) Parts Catalog Parts Catalog CD-ROM Principles of Operation Service Manual Troubleshooting Manual *Worldwide Sales And Service Directory

Literature Number GN3433EN GN2055EN OM3749EN OM3656EN OM3750EN OM4119EN OM3349EN OM3752EN OM3753EN OM3654EN MT4015EN MT4085EN PC2456EN CD2456EN PO4016EN SM4014EN TS3989EN SA2229EN

* Also Available On The Internet At www.allisontransmission.com

8–2


F OLDOUT 1

1

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

— — — — — — — — — — — — — — — — — — — — — — — — — —

2

3

4

5

6

7

8

9

10

11

12

13

14

Lockup clutch/ damper Converter turbine Converter stator Converter pump Oil pump Front support Main housing Main shaft C3 clutch C4 clutch P2 sun gear C5 clutch P3 sun gear Output shaft Rear cover C5 piston P3 module Oil level sensor Control module P2 module P1 module C2 clutch C1 clutch Turbine shaft Ground sleeve Converter housing module

26

25

24

23

22

21

20

Foldout 1. 4000 Product Family Transmission (Close Ratio)—Cross Section

19

18

17

16

15

V05513.01.02

F OLDOUT 2 1

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28

— — — — — — — — — — — — — — — — — — — — — — — — — — — —

2

3

4

5

6

7

8

9

10

11

12

13

14

15

Lockup clutch/damper Converter turbine Converter stator Converter pump Charging oil pump Front support Breather Main housing Main shaft C3 clutch C4 clutch P2 sun gear C5 clutch P3 sun gear Output shaft Rear cover C5 piston P3 module Oil level sensor Control module P2 module P1 module C2 clutch C1 clutch Turbine shaft PTO drive gear Ground sleeve Converter housing module

28

27

26

25

24

23

22

21

Foldout 2. 4500 Model (Wide Ratio) Transmission With PTO Provision—Cross Section

20

19

18

17

16

V05515.01.02

F OLDOUT 3 1

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27

— — — — — — — — — — — — — — — — — — — — — — — — — — —

2

3

4

5

6

7

8

9

10

11

12

13

14 15

16

17

Lockup clutch/ damper Converter turbine Converter stator Converter pump Charging oil pump Front support Main housing Main shaft C3 clutch C4 clutch P2 sun gear C5 clutch P3 sun gear Retarder stator Retarder rotor Retarder module Retarder housing C5 piston P3 module Control module P2 module P1 module C2 clutch C1 clutch Turbine shaft Ground sleeve Converter housing module

27

Foldout 3.

26

25

24

23

22

21

4000 Product Family (Close Ratio) Transmission With Retarder—Cross Section

20

19

18

V05514.01.01


Legend For Foldout 3,A Is On The Opposite Side Of This Page.


Foldout 3,A

4000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4 th GENERATION Legend For Foldout 3,A

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35

Foldout 3,A

— — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — —

Lockup clutch/damper Converter turbine Converter stator Converter pump Charging oil pump Front support Main housing Main shaft C3 clutch C4 clutch P2 sun gear Shim C5 clutch P3 sun gear C5 piston assembly C6 adapter housing module C6 clutch P4 ring gear Rear cover Output shaft C6 piston P4 planetary P4 sun gear Selective shim P4 shaft flange P3 planetary Oil level sensor Control valve assembly P2 planetary P1 planetary C2 clutch C1 clutch Turbine shaft Converter ground sleeve Converter housing


F OLDOUT 3,A 1

2

3

35

4

6

5

34

7

8

9

10

11

12

13

14

15

33

16

25

32

31

30

29

28

27

26

Foldout 3,A. 4700 and 4800 Model Transmission—Cross Section

17

18

24 23 22

19

20

21

V05265.05.00


Legend For Foldout 3,B Is On The Opposite Side Of This Page.


Foldout 3,B

4000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4 th GENERATION Legend For Foldout 3,B 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36

Foldout 3,B

— — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — —

Lockup clutch/damper Converter turbine Converter stator Converter pump Charging oil pump Front support Main housing Main shaft C3 clutch C4 clutch P2 sun gear Shim C5 clutch P3 sun gear C5 piston assembly C6 adapter housing module C6 clutch P4 ring gear Retarder stator Retarder rotor Retarder and output shaft module Output shaft C6 piston P4 planetary P4 sun gear Selective shim P4 shaft flange P3 planetary Control valve assembly P2 planetary P1 planetary C2 clutch C1 clutch Turbine shaft Converter ground sleeve Converter housing


F OLDOUT 3,B 1

2

3

36

4

5

6

35

8

7

9

10

11

12

13

14

15

34

16

27

33

32

31

30

29

28

Foldout 3,B. 4700 and 4800 Model Transmission With Retarder—Cross Section

17

18

26 25 24

19

20

21

22

23

V09805.00.00


Legend For Foldout 3,C Is On The Opposite Side Of This Page.


Foldout 3,C

4000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4 th GENERATION Legend For Foldout 3,C 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38

Foldout 3,C

— — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — —

Lockup clutch/damper Converter turbine Converter stator Converter pump Charging oil pump Front support Oil vent assembly Main housing Main shaft C3 clutch C4 clutch P2 sun gear Shim C5 clutch P3 sun gear C5 piston assembly C6 adapter housing module C6 clutch P4 ring gear Retarder stator Retarder rotor Retarder and output shaft module Output shaft C6 piston P4 planetary P4 sun gear Selective shim P4 shaft flange P3 planetary Control valve assembly P2 planetary P1 planetary C2 clutch C1 clutch Turbine shaft PTO drive gear Converter ground sleeve Converter housing


F OLDOUT 3,C 1

2

3

38

4

37

36

5

35

6

34

7

8

9

10

11 12

13

33

14

15

16

29 32

31

17

28

18

27

30

Foldout 3,C. 4700 and 4800 Model Transmission With Retarder and PTO Provision—Cross Section

19

26

20

25

21

22

23

24 V05646.05.00

F OLDOUT 4,A 3

2 4

5 6

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

— — — — — — — — — — — — — — — — — — — — — —

Crank hub adapter Bolt, M8 x 1.25 x 20 (12), A Flexplate assembly Bolt plate (6) Flexplate Flexplate (3) Bolt, M8 x 1.25 x 25 (28), A Flexplate adapter assembly Ring gear Flexplate adapter Wear plate Bolt, M8 x 1.25 x 45 (12), A Ring gear assembly Ring gear Flexplate Flexplate (3) Bolt, M8 x 1.25 x 25 (28), A Flexplate adapter Wear plate Bolt, M8 x 1.25 x 25 (12), A Flexplate assembly Bolt plate (6)

23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41

— — — — — — — — — — — — — — — — — — —

7

Flexplate Flexplate Bolt, M8 x 1.25 x 25 (28), A Flexplate adapter assembly Ring gear Flexplate adapter Wear plate Bolt, 5⁄16-18 x 2 (6), A Bolt, M8 x 1.25 x 25 (12), A Flexplate assembly Bolt plate (6) Flexplate Flexplate Bolt, M8 x 1.25 x 25 (16 or 28), A Flexplate adapter assembly Ring gear Flexplate adapter Wear plate Bolt (2), A

Torque A

N·m 24–29

lb ft 18–21

8 9

1

10

11

13

12 14

15 16 17 18

20

19

21 22 23 24 25

26 27 28

31

32 33

29

34

30

35 36

37 38 39

40 41

L00182

Foldout 4,A. Flexplate and Adapter—Exploded View

F OLDOUT 4,B

1 2

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

— — — — — — — — — — — — — — — — — — — — —

Converter end plug O-ring Converter end plug, A Torque converter module Nut (36), B Torque converter cover assembly Converter cover Bushing Lockup piston sealring Lockup piston assembly Lockup piston sealring Damper assembly Lockup clutch backplate Bolt, M8 x 1.25 (44), C Thrust bearing assembly Turbine hub sealring Turbine hub assembly Thrust bearing assembly Star plate Stator assembly Retaining ring

22 23 24 25 26 27 28

29 30 31 32 33 34

— — — — — — — — — — — — — — —

Stator thrust plate assembly LH stator thrust washer Stator race Stator spring (13) Stator roller (13) Stator and cam assembly Shim, 0.27 mm (0.011 inch) Shim, 0.48 mm (0.019 inch) Shim, 0.711 mm (0.028 inch) Thrust bearing race Pump thrust bearing assembly O-ring Thrust bearing race Torque converter pump assembly T-head bolt (36)

7

8

9

6

3

10 4

11 5 12

16

13

17

15 18 19 21 22 23 24 26 27

14 28

Torque A B C

N·m 50–60 30–35 24–29

lb ft 37–44 22–26 18–21

29 25

30 31

20

32

33 34

V06850.01.00

Foldout 4,B. Torque Converter Module—Exploded View


Legend For Foldout 5 Is On The Opposite Side Of This Page.


Foldout 5

4000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4 th GENERATION Legend For Foldout 5

A

B

1 — Converter housing module

1 — Converter housing module

2 — Breather assembly, M12 x 1.5, A

2 — Bolt, M10 x 1.5 x 35 (11), A

3 — Converter housing

3 — Bearing retainer assembly

4 — Speed sensor assembly

4 — Oil seal assembly

5 — O-ring

5 — Bearing retainer/bushing assembly

6 — Speed sensor retainer

6 — Bushing

7 — Bolt, M8 x 1.25 x 20, B

7 — Bearing retainer

8 — Sensor shipping cover

8 — Sealring

9 — Converter housing gasket

9 — Sealring

10 — Bolt, M10 x 1.5 x 35 (25), C Torque A B C

N·m 12–16 24–29 51–61

10 — PTO gear assembly lb ft 9–12 18–21 38–45

11 — Ball bearing (2) 12 — PTO gear 13 — Oil pump drive hub 14 — Sealring 15 — Speed sensor assembly 16 — O-ring 17 — Speed sensor retainer 18 — Bolt, M8 x 1.25 x 20, B 19 — Converter housing 20 — Breather assembly, M12 x 1.5, C 21 — Bolt, M10 x 1.5 x 35 (25), A 22 — Converter housing gasket 23 — Sensor shipping cover 24 — Bolt, M10 x 1.5 x 25 (10), A 25 — PTO cover 26 — PTO cover gasket 27 — Bolt, M10 x 1.5 x 25 (10), A 28 — PTO cover 29 — PTO cover gasket Torque A B C

Foldout 5


N·m 51–61 24–29 12–16

lb ft 38–45 18–21 9–12

F OLDOUT 5 A

B 1

2

1 4

3

24

2

25

5

3

26 6 7

8 4

9 20

6

15

10 10

5

16

11

9 7

17

18

12 21

13 11 14

23 19

8

22

29 28 27

V05395

Foldout 5,A. Converter Housing Module—Exploded View

V03918.02

Foldout 5,B. Converter Housing Module With PTO Provision—Exploded View




Foldout 6


A 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

— — — — — — — — — — — — — — — — — — — — — — — — — —

Bolt, M10 x 1.5 x 65 (7), A Bolt, M10 x 1.5 x 35 (7), A Front support module O-ring Oil seal assembly Bolt, M10 x 1.5 x 65 (8), A Pump housing assembly Bushing Pump housing Pump housing (PTO) Pump gear set Bushing Wear plate Bolt, M10 x 1.5 x 25 (14), A Front support assembly (complete) Ground sleeve (PTO) Ground sleeve Front support assembly Dowel pin, 10 x 32 (2) Front support Front support sleeve Spring Ball Dowel pin Sealring (3) Roller bearing assembly

Torque A

N·m 51–61

lb ft 38–45

B 1 2 3 4 5 6

— — — — — —

Rotating clutch module O-ring Turbine shaft assembly Turbine shaft Turbine shaft bushing Turbine shaft assembly (PTO)

Foldout 6

7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43

— — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — —

Turbine shaft (PTO) Sealring (3) Rotating clutch drum Thrust bearing Rotating clutch hub assembly (complete) Rotating clutch hub bushing Rotating clutch hub assembly Thrust bearing Turbine shaft retaining ring C2 piston sealring C1 piston sealring External sealring C2 piston C2 spring assembly C2 spring plate Internal retaining ring C1 sealring C1 piston C1 spring assembly Rotating clutch balance piston Rotating clutch balance piston sealring Balance piston retaining ring C1 clutch apply plate C1 friction plate (7) C1 reaction plate (6) C1 clutch backplate External retaining ring C1 drive hub Thrust bearing (2) C2 drive hub C2 reaction plate (7) C2 friction plate (7) C2 clutch backplate Internal retaining ring Sun gear assembly (complete) Thrust bearing Internal retaining ring


F OLDOUT 6 A

B

2

3 4 8

2

9

5 7

7

8

4

6

12

9

5

3

1

11

10

13

21 14

22

1

15 23

10

16

17 18

24

11

19

6

25 12

13

16

20

26

15

27 28 14 17

29

33

18 20

30

34

19

31

35 36 21

35 37

25 26

38

32

23 22 24

39 40 41 42 V02818.01

Foldout 6,A. Front Support and Oil Pump Module—Exploded View

43

Foldout 6,B. Rotating Clutch Module—Exploded View

V06870.01.00

F OLDOUT 7

3

2 4

1 2 3 4 5 6 7 8 9 10 11

— — — — — — — — — — —

12 13 14 15 16 17 18 19 20 21

— — — — — — — — — —

C3/C4 clutch assembly Bolt, M10 x 1.5 x 90 (14), A C3 backplate assembly (complete) Clutch backplate assembly P1 ring thrust plate (6) P1 planetary ring gear C3 clutch friction plate (5) C3 clutch reaction plate (5) C3 piston return plate assembly C3 clutch piston assembly C3 clutch housing assembly (complete) P1 ring thrust plate (6) C3 clutch housing C4 clutch reaction plate (6) C4 clutch friction plate (5) C4 piston return plate assembly C4 clutch piston assembly C4 clutch housing C5 clutch friction plate (8) C5 clutch reaction plate (9) Bolt, M10 x 1.5 x 35 (14), A

22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37

— — — — — — — — — — — — — — — —

Internal harness connector cap Identification plate Rivet Bolt, M8 x 1.25 x 20, B Speed sensor assembly O-ring Speed sensor bracket Speed sensor shipping cover Main housing assembly Main housing Recoil insert Fill tube seal Oil fill tube Tapping screw, M8 x 25, B Oil fill tube bracket Oil level indicator Torque A B

N·m 51–61 24–29

1 5 6 7 8

14

11 15 9

29

10 12

26 16

27

13 17

25 28

34 37

18

35 23 24 36

lb ft 38–45 18–21

33

22 31 21

19

20

30

32 V04763.06.00

Foldout 7. Main Housing Module—Exploded View

F OLDOUT 8 WIDE RATIO 4

1 5

2 6

3

1 1 1 1 1 1 1 1 2

— — — — — — — — —

Shim (non-selective)—4700 and 4800 models Shim (selective)—except 4700 models, 0.245–0.295 mm (0.0097–0.0116 inch) (marked with 1 slot) Shim (selective)—except 4700 models 4070, 0.515–0.565 mm (0.02103–0.0222 inch) (marked with 2 slots) Shim (selective)—except 4700 models, 0.785–0.835 mm (0.0310–0.0328 inch) (marked with 3 slots) Shim (selective)—except 4700 models, 1.055–1.105 mm (0.0416–0.0435 inch) (marked with 4 slots) Shim (selective)—except 4700 models, 1.325–1.375 mm (0.0522–0.0541 inch) (marked with 5 slots) Shim (selective)—except 4700 models, 1.595–1.645 mm (0.0628–0.0647 inch) (marked with 6 slots) Shim (selective)—except 4700 models, 1.865–1.915 mm (0.0735–0.0753 inch) (not marked with slots) Thrust bearing

Wide Ratio 3 4 5 6 7

— — — — —

Main shaft module External retaining ring (spiral) P2 sun gear Bearing spacer Main shaft

7

Close Ratio 3 4 5 6 7 8

— — — — — —

Main shaft module External retaining ring (spiral) P2 sun gear Bearing spacer P3 sun gear Main shaft

CLOSE RATIO 4 1 5

2 6

3

7

8

V06878

Foldout 8. Main Shaft Module—Exploded View




Foldout 9


A

B

1 — P1 planetary module

1 — P2 planetary module

2 — Internal retaining ring

2 — Retaining ring

3 — P1 planetary carrier assembly




5 — P1 indexing ring


6 — P1 pinion spindle (6)

6 — Carrier and bushing assembly

7 — P1 planetary carrier/bushing assembly

7 — P2 planetary carrier


8 — Bushing

9 — P1 carrier bushing

9 — Thrust washer (4)

10 — P1 thrust washer (6)

10 — Roller bearing (8)

11 — P1 pinion gear (6)


12 — Roller bearing assembly (12)

12 — Thrust washer (4)


13 — P2 pinion spindle (4)

14 — Thrust bearing assembly


15 — P2 ring gear

15 — P3 planetary ring gear

Foldout 9


F OLDOUT 9,A,B A

B

1

2

1 2

14 15

3

4

3 5

4 5

6 7 7

15

8

8 9

14

6 9 13

10 10

11

11

12

12 13

V06852 V03630.01

Foldout 9,A. P1 Planetary Module—Exploded View

Foldout 9,B. P2 Planetary Module—Exploded View

F OLDOUT 9,C 1 — P3 carrier module

24 — Pressure tap plug

2 — Internal retaining ring, 219 OD

25 — O-ring, 8.92 ID


26 — Ball bearing assembly


27 — C6 reaction plate (9)

5 — P4 shaft flange

28 — C6 friction plate (8)

6 — Shim locating ring

29 — C6 backplate

7 — P3 planetary spindle (4)

30 — P4 sun gear


31 — Thrust bearing


32 — P4 carrier assembly

2

18 — Piston 19 — Piston OD sealring 20 — Piston ID lip-type sealring 21 — Adapter housing assembly 22 — Adapter housing 23 — Plug assembly (2), B

13

10 8

35 — Indexing ring

17 — Piston return spring assembly

20

9

12 — — — — — — — — —

16 — External retaining ring

19

6 8

34 — Internal retaining ring, 235 OD

15 — Piston assembly

18

1

7

11 — Flange head bolt, M12 x 1.75 x 45 (14), A

14 — C6 adapter housing module

15

5


13 — Adapter housing gasket

17 4

10 — Roller bearing assembly (8) Shim, (selective), 0.27 mm Shim, (selective), 0.54 mm Shim, (selective), 0.81 mm Shim, (selective), 1.08 mm Shim, (selective), 1.35 mm Shim, (selective), 1.62 mm Shim, (selective), 1.89 mm Shim, (selective), 2.16 mm Shim, (selective), 2.43 mm

14

16

12 3

11

36 — P4 carrier and bushing assembly 37 — P4 carrier 22

38 — P4 carrier bushing

26 27

21


28

40 — P4 planetary thrust washer (12) 23

41 — P4 pinion gear (6) 42 — Caged needle bearing (12)

24

43 — C6 clutch drum hub

25 23


25 24

30

45 — P4 ring gear and hub assembly

29

46 — P4 ring gear

31 32

47 — P4 ring gear hub 48 — Retaining ring

43

49 — Star tolerance ring Torque A B

N·m 100–120 10–13

44

lb ft 74–88 7–10

46

45

47

33 34

37 35

39

38

36

48

49

41 42 40 V06854.01.00

Foldout 9,C. P3 Planetary Module and C6 Adapter Housing Module (4700 and 4800 Models)—Exploded View

F OLDOUT 10,A 1 — Rear cover gasket

25 — Internal sealring

2 — Bolt, M12 x 1.7 x 45 (19), A

26 — Roller bearing cup

3 — Washer

27 — Rear cover assembly

4 — Rear cover and P3 planetary module

28 — Brass washer


29 — Plug, 3⁄4-16 straight thread, B

6 — Output shaft assembly

29 — Tachograph plug, C

7 — Bushing

30 — Rear cover

8 — Output shaft

31 — Dowel pin (2)



21

3


12 — Thrust washer

35 — Bolt, M8 x 1.25 x 20, B




37 — Cone and roller bearing assembly


38 — Belleville washer


39 — Bearing retainer locknut, D

17 — Roller bearing assembly (4 groups of 2)

40 — Output seal assembly


41 — Speed sensor shipping cover

22 — Spring and retainer assembly 23 — C5 clutch piston 24 — Piston sealring

2

20 24



4

23

5

33 — O-ring


1 22



19

35

25

32 26

6

34

27

7

41

33

30 9

8

10

31 11 29 28

12 13

31

Torque A B C D

N·m 100–120 24–29 60–67 74–88

lb ft 74–88 18–21 45–49 55–65

14

36

15 16

37 17

38 18

39 40

V06856.01.00

Foldout 10,A. Rear Cover and P3 Planetary Module—Exploded View

F OLDOUT 10,B 1 — Rear cover gasket 2

2 — Bolt, M12 x 1.75 x 45 (14), A 3 — Bracket

3

4 — Bolt, M12 x 1.75 x 222.5 (5), A 5 — Rear cover module 6 — Output shaft assembly 1

7 — Bushing 8 — Output shaft 9 — Roller bearing assembly

4

7


6

5

11 — External retaining ring 12 — C5 piston spring return retainer assembly 13 — C5 clutch piston

8 9 11

14 — External sealring

12

15 — Internal lip-type sealring 16 — Roller bearing cup

13


14

10

18 — Rear cover

23

15

19 — Tachograph plug, B

22 16

20 — Washer

24

17


30

25

18

22 — Speed sensor assembly 23 — Self-locking bolt, M8 x 1.25 x 20, C 24 — Speed sensor retainer 25 — O-ring

26 27

26 — Roller bearing assembly

19 20 28

27 — Belleville washer 28 — Bearing retainer locknut

29 21

29 — Output seal assembly 30 — Sensor shipping cover Torque A B C

N·m 100–120 60–67 24–29

lb ft 74–88 44–50 18–21

V06858.01.00

Foldout 10B. Rear Cover and Output Shaft Module (4700 and 4800 Models)—Exploded View

4000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4 th GENERATION Legend For Foldout 10,C 1 — Stator housing gasket

31 — Retarder housing assembly

2 — Retarder and P3 planetary module



33 — Valve plug

4 — Output shaft assembly

34 — O-ring

5 — Bushing

35 — Valve spring

6 — Output shaft

36 — Retarder valve


37 — Spring pin


38 — Retarder housing subassembly


39 — Tachograph plug, A

10 — Thrust washer

40 — Washer


41 — Retarder housing


42 — Gasket


43 — Cover


44 — Bolt, M8 x 1.25 x 25 (9), B

15 — Roller bearing assembly (4 groups of 2)

45 — Temperature sensor assembly (TID2)


46 — O-ring


47 — Retainer

18 — Retarder stator assembly

48 — Bolt, M8 x 1.25 x 20, B


49 — Valve plug

20 — Spring and retainer assembly


21 — C5 clutch piston


22 — C5 piston outer sealring

52 — Bolt, M8 x 1.25 x 25 (3), C

23 — C5 piston inner sealring



54 — O-ring

25 — Retarder stator


26 — O-ring

56 — Bolt, M8 x 1.25 x 20, B

27 — Retarder sealring


28 — Retarder housing gasket

58 — Belleville washer

29 — Rotor assembly

59 — Bearing retainer locknut, D

30 — Retarder sealring

60 — Oil seal assembly


Foldout 10,C

4000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4 th GENERATION Legend For Foldout 10,C (cont’d) 61 — Sensor shipping cover

87 — Retarder control valve cover gasket

62 — Bolt, M12 x 1.75 x 55 (12), E

88 — Retarder control valve cover

63 — Separator plate

89 — Bolt, M8 x 1.25 x 30 (3), B

64 — Retarder connector cover

90 — Pressure tap plug assembly

65 — Retarder control valve assembly 66 — Straight thread plug assembly

91 — O-ring 92 — Pressure tap plug, F

67 — Straight thread plug

93 — Bolt, M8 x 1.25 x 115 (9), B

68 — O-ring

94 — Bolt, M12 x 1.75 x 165 (4), E

69 — Spring 70 — Exhaust backfill valve

95 — Bolt, M12 x 1.75 x 105 (2), E

71 — Solenoid and connector assembly

96 — Bolt, M10 x 1.5 x 160 (4), G

72 — Solenoid

97 — Gasket

73 — O-ring seal

98 — Jumper manifold

74 — O-ring

99 — Bolt, M10 x 1.5 x 30, G

75 — Retarder control valve body

100 — Remote side manifold

76 — Solenoid retaining pin

101 — Bolt, M10 x 1.5 x 160 (3), G

77 — Regulator valve 78 — Spring 79 — Straight thread plug assembly 80 — O-ring 81 — Straight thread plug 82 — Straight thread plug assembly 83 — Straight thread plug

Torque A B C D E F G

N·m 60–67 24–29 12–15 * 100–120 10–13 51–61

lb ft 45–49 18–21 9–11 * 74–88 7–10 38–45

84 — O-ring 85 — Spring 86 — Relay valve

Foldout 10,C

* Before module is installed 193–207 N·m (143–152 lb ft); After Module is installed 74–88 N·m (55–64 lb ft)


F OLDOUT 10,C 1

17 19 20

21

18 22

3 2 4

23

5

24

25

6 7 8 26 9 10 11 12 13 14 15

65 16 66 67 68 69 71 70

62 48

52 27

45

72 73 74

47 46

90

89

64

91

92

93

75

61

88

28

87

63 76 54 55 56

30

29

38 39

41 49

40

50

51

37

86

77 78 79 80 81

53

85 82 84 83

57 58 59

31 35 32

36

33 34

60

42 43 44 96

94 91 95

100 97

101 98 99

Foldout 10,C. Retarder and P3 Module—Exploded View

V06859.01.01

F OLDOUT 10,D 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52

— — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — —

Stator housing gasket Retarder module Output shaft assembly Bushing, 28 ID Output shaft Cone and roller bearing assembly Retarder stator assembly External retaining ring, 181 ID C5 piston return spring and retainer assembly C5 clutch piston External sealring, 315.17 ID Internal lip-type sealring, 214.06 OD Roller bearing cup Retarder stator housing O-ring, 11.48 ID Rotating sealring, 146 OD Retarder housing gasket Rotor assembly Rotating sealring, 146 OD Flange head bolt, M8 x 1.25 x 25 (3), A Retarder housing assembly Internal retaining ring, 45.82 OD Valve plug O-ring, 34.6 ID Valve spring, 36.17 OD x 114.3 Retarder valve Spring pin, 5 x 45 Plug and retarder housing assembly Tachograph plug, M18 x 1.5, B Washer, M18 Retarder housing Gasket Cover Bolt, M8 x 1.25 x 25 (9), D Temperature sensor assembly O-ring Thermistor protection bracket Self-locking bolt, M8 x 1.25 x 20, D Valve plug Internal retaining ring, 45.82 OD Roller bearing cup Cone and roller bearing assembly Belleville washer Bearing retainer locknut, C Oil seal assembly Speed sensor assembly O-ring, 15.37 ID Speed sensor retainer Self-locking bolt, M8 x 1.25 x 20, D Sensor cover Flange head bolt, M12 x 1.75 x 55 (12), E Separator plate

53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90

— — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — —

Retarder connector cover Retarder control valve assembly Straight thread plug assembly Straight thread plug O-ring Spring Exhaust backfill valve Solenoid and connector assembly Solenoid O-ring seal O-ring Retarder control valve body Solenoid retaining pin Regulator valve Spring Straight thread plug assembly O-ring Straight thread plug Straight thread plug assembly Straight thread plug O-ring Spring Relay valve Retarder control valve cover gasket Retarder control valve cover Bolt, M8 x 1.25 x 30 (3), B Pressure tap plug assembly O-ring Pressure tap plug, F Bolt, M8 x 1.25 x 115 (9), B Gasket Jumper manifold Bolt, M10 x 1.5 x 30, G Remote side manifold Bolt, M10 x 1.5 x 354 (3), G Bolt, M10 x 1.5 x 345 (7), G Bolt, M12 x 1.75 x 350 (4), E Bolt, M12 x 1.75 x 105 (2), E Torque A B C D E F G

N·m 12–15 60–67 * 24–29 100–120 10–13 51–61

lb ft 9–11 45–49 * 18–21 74–88 7–10 38–45

1 4

3 5 6

8

9 10

7 11

2 12 13

14 15

54 55 56 57 58 60 59 38

20 16

35

61 62 63

51

37 36

50

79

78

53

80

81

82

64 77

17

76

52 65 47 48 49

19

18

28 29

31 39

30

40

75

66 68 67 69 70

46 41

27

74 71 73 72

42 43 44

21 25 22

26

23 24

* Before module is installed 193–207 N·m (143–152 lb ft); After Module is installed 74–88 N·m (55–64 lb ft)

45

32 33 34

89 88 86 83 90

84 85

Foldout 10D. Retarder and Output Shaft Module (4700 and 4800 Models)—Exploded View

87 V06860.01.01

4000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4 th GENERATION Legend For Foldout 11 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50

— — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — —

Control valve module Suction filter assembly kit Bolt, M6 x 1.0 x 30, A Suction filter assembly Suction filter Face seal Suction filter gasket Control harness assembly Connector assembly Electronic connector Seal Sealring Standoff assembly Cavity plug Bolt, 20F connector, C Temperature sensor (OILT) Connector assembly Connector, 2-Way Pin terminal Pin terminal Secondary lock Connector Assembly (OLS) Terminal Terminal Connector, 2-way Connector assembly (SS1) Terminal Terminal Connector, 2-way Channel Solenoid connector assembly (SS2) Connector, 2-way Terminal Terminal 2-Way solenoid connector (PCS4) 2-Way solenoid connector (PCS5) 2-Way solenoid connector (PCS6) 2-Way solenoid connector (PCS1) 2-Way connector (C3 pressure switch) Terminal Terminal 2-Way connector 2-Way solenoid connector (TCC) 2-Way solenoid connector (PCS2) 2-Way solenoid connector (PCS3) Shoulder bolt, M6 1.0 x 45 (3), B Bracket Bolt, M6 1.0 x 45 (2), A Face Seal Accumulator spring (2)

51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99

— Accumulator plug (2) — Accumulator plug (2) — Accumulator spring (2) — Switch assembly — Switch — Bracket — Bolt, M6 x 1.0 x 95 (12), A — Solenoid body assembly — Body assembly valve and pin — Valve body — Pin (3) — Variable bleed solenoid (TCC) — O-ring — O-ring — TCC valve — Spring — Variable bleed solenoid (PCS1) — O-ring — O-ring — PCS1 valve — Spring — Variable bleed solenoid (PCS2) — O-ring — O-ring — PCS2 valve — Spring — Clip — Diagnostic valve — Spring — Variable bleed solenoid (PCS3) — O-ring — O-ring — PCS3 valve — Spring — Variable bleed solenoid (PCS4) — O-ring — O-ring — PCS4 valve — Spring — Variable bleed solenoid (Main Mod) — O-ring — O-ring — Solenoid separator plate — Bolt, M6 x 1.0 x 60 (2), A — Main valve body assembly — Retention pin 5 OD x 43 — Converter flow valve — Spring — Valve stop


Foldout 11

4000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4 th GENERATION Legend For Foldout 11 (cont’d) 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 141 142 143

— — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — —

Retention pin 3 OD 43 Lube regulator valve Spring Valve stop Retention pin 5 OD x 43 Main regulator valve Spring Valve stop Control main valve Spring Clip Retention pin, 2.5 OD x 40 Solenoid assembly O-ring O-ring Control valve body Spring pin, 5 OD x 55 C2 latch valve Spring Valve stop Retention pin, 5 OD x 43 Exhaust backfill valve Spring Valve stop Retention pin, 5 OD x 43 C1 latch valve Spring Valve stop Retention pin, 5 OD x 43 Converter regulator valve Spring Valve stop Retention pin 3 OD x 43 Bolt M6 x 1.0 x 45 (2), A Oil level sensor assembly Ferrule Viton® (2) Separator plate Channel plate gasket Channel plate assembly Dowel pin (2) Channel plate Oil drain plug assembly, D O-ring Pressure tap plug assembly

Foldout 11

144 145 146 147 148 149 150 151 152 153 154 155 156 157 158 159 160 161 162 163 164 165 166 167 168 169 170 171 172 173 174

— — — — — — — — — — — — — — — — — — — — — — — — — — — — — — —

O-ring Pressure tap plug (9), A Filter cover (2) Filter cover gasket (2) O-ring (2) O-ring (2) Oil filter (2) Accumulator plug Accumulator spring Accumulator retaining bracket Bolt, M6 x 1.0 x 60 (4), A C6 clutch body assembly C6 clutch body Spring Retention pin 2.5 OD x 30 C6 enable valve Solenoid assembly O-ring O-ring Solenoid protective plate Push-on nut Spring C6 clutch trim valve Solenoid assembly O-ring O-ring Solenoid retaining bracket Screw Case gasket Bolt, M10 x 1.5 x 55 (34), E Bolt, M10 x 1.5 x 100 (25, 4 inch sump), E Torque

N·m

lb ft

A B C D E

10–13 5–8 2.5–3.5 25–32 51–61

7–10 4–6 22–31 lb inch 18–24 38–45


F OLDOUT 11 1 (Cont'd) 93

99

95 98

10 9

1

96

100

128

11

132

8 12

104

43 44

39 42

103 101

107 135

106

111

14

133 134

102

124 120

94

97

110

105

46

109

45

40 41

108

13

112

3 30

129

38

2

26 6 5

126

23

36

7

34

33

123

117 118

20 19

119 18

150

16

17

31

116

122

24

32

172

121

21

22

35

115

127 15

25

114

125

131

29 28 27

37

4

113

130

136 137

149 57

54

47

154

62 48

55

64

49 66

53

56

67

139 146

151

68

51

140

69 70

91

92

61

72

157

73 74

59 85

86

60 76

87

159

160 161

75

171

158

162 141

89

143

88

80

155

156

71 90

81

170 167

82 84 83

138

147

152

52

58

153

65

50

148

63

169 168

163 164 166

78

144

142

145

165

79 77

173

V09483.00.00

174

Foldout 11. Control Valve Module—Exploded View

V09482.00.00




Foldout 12


A

11 — Temperature gauge kit

1 — Output flange

12 — Temperature sender adapter

2 — Output flange assembly

13 — Shipping plug (2)

3 — Slinger

14 — Straight fitting

4 — Output flange

15 — Shipping plug assembly

5 — Output flange

16 — Cooler port plug (2)

6 — Output flange

17 — Pilot screw (2)

7 — Output yoke assembly

18 — PTO gasket

8 — Slinger

19 — Bolt, M10 x 1.5 x 35 (8), A

9 — Output yoke

20 — Clutched drive PTO assembly

10 — Output yoke

21 — Hose assembly

11 — Output yoke

22 — 90 degree hose fitting

12 — Dropbox coupling

23 — Pilot screw (2)

13 — Shipping cover

24 — PTO gasket

14 — Shipping cover

25 — Bolt, M10 x 1.5 x 25 (8), A

15 — O-ring, 75.9 mm ID

26 — Hose assembly

16 — O-ring, 9.1 mm ID

27 — 90 degree fitting

17 — Retaining plate

28 — Bolt, tie rod, 3⁄8-24 x 7 (4) for use with steel end cap

18 — Bolt, M14 x 2 x 70, B Torque A B

N·m 30–35 70–80

28 — Bolt, tie rod, 3⁄8-16 x 75⁄8 (4) for use with aluminum end cap lb ft 22–26 51–60

29 — Steel gas cap 29 — Aluminum gas cap 30 — O-ring (2) 91.7 mm ID for use with steel end cap 30 — O-ring (2) 101.6 mm ID for use with aluminum end cap

B 1 — Converter shipping bracket (3)

31 — Steel hydraulic cap

2 — Bolt, M10 x 1.5 x 25 (3), A

31 — Aluminum hydraulic cap

3 — Rear support bracket (front)

32 — External lip-type seal, 31⁄2 inch ID

4 — Rear support bracket (rear)

33 — Sealring

5 — Remote mount cooler

34 — Piston

5 — Retarder oil cooler

35 — Cylinder body for use with steel end cap

6 — Remote mount gasket

35 — Cylinder body for use with aluminum end cap

7 — Remote mount manifold 8 — Cooler port cover 9 — Bolt, M10 x 1.5 x 28 (6), A

Torque A

10 — 90 degree fitting

Foldout 12


N·m 51–61

lb ft 38–45

F OLDOUT 12A,B B

A

3 1 4 5 2

3

13

4

14 15 16 5 11 8

10

12 120 250

10 0

0 12

31

6

7

19 17

29 28

9

TRANS OIL TEMP

20

9

30

7

°C 300 °F

6

30 8

150

18

32

10 33 13

21 22

34 32 33

11

1

2

15 24

16

25 1

17

2

18 12 14

27 23

26 V07331.01.00

V07030.03.00

Foldout 12,A. Output Flange And Yoke—Exploded View

Foldout 12,B. Support Equipment—Exploded View

F OLDOUT 12,C 1

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

— — — — — — — — — — — — — — — — — — — — — — — —

Bolt, M10 x 1.5 x 60 (16), B Hose adapter Gasket, manifold to water (2) Gasket, integral cooler Bolt, M8 x 1.5 x 25 (6), A Gasket, manifold to cooler (2) Cooler, integral Bolt, M10 x 1.5 x 50, B Bolt, M10 x 1.5 x 187.5 (7), B Bolt, M12 x 1.75 x 195 (8), C Manifold assembly, integral cooler Plug assembly, shipping, SAE No. 16 O-ring Plug assembly, pressure tap O-ring, 11.6 mm ID Manifold, integral, strapped Plug assembly, pressure tap O-ring, 8.9 mm ID Plug assembly, pressure tap Plug, pressure tap Plug assembly, pressure tap O-ring, 9.3 mm ID Plug assembly, pressure tap O-ring, 8.9 mm ID

2

3 11

12 4 13

24

15 14

23

16

21 22

17 18 19

10

20

9 5

Torque A B C

N·m 24–29 51–61 100–120

lb ft 18–21 38–45 74–88

8 6 6

7

V07034.01.00

Foldout 12,C. Integral Retarder Sump Cooler—Exploded View

F OLDOUT 13 LOCKUP

LUBE FILTER

COOLER

CONVERTER OUT

LUBE

LUBE

CONVERTER IN

TORQUE CONVERTER

ALLISON 4th GENERATION HYDRAULIC SCHEMATIC — NEUTRAL 3000 AND 4000 PRODUCT FAMILIES

Orifice

EX

EX

CONVERTER REGULATOR

CONVERTER FLOW

EX

LUBE REGULATOR

REAR SPLITLINE

TCC *

EX

EX

PCS1 N/O

N/C

EX

PCS2 N/O

EX

PCS4 N/C

EX

PCS3 N/C

EX

EX

EX

EX

Accumulator

Accumulator

Accumulator

EX

EX

CONTROL MAIN

Accumulator

EX

EX

MAIN EX

EX

MAIN FILTER

SS1 N/C

Pressure Relief

EX

Orifice

*** PS1

DIAGNOSTIC

EX

PCS6 N/C

EX

EX

SS2 N/C

EX

MAIN REGULATOR

PUMP

EX

6-Speed Only

EX

EXHAUST BACKFILL

Accumulator

MAIN MOD ** N/C

EX

C2 LATCH

EX

EX

C1 LATCH

EX

SUCTION FILTER

EX

C1

C2

C1

C3

C2

C4

C3

C5

C4

SUMP

C6

C5

C6

NOTES: LEGEND: * TCC Solenoid is generally ON from 2nd-range thru 6th-range MAIN ** Main Mod Solenoid may be ON in Reverse, Neutral, Low (7-speed), CONTROL MAIN 1st, or 2nd as determined by calibration. EXHAUST *** PS1 = Diagnostic Pressure Switch SUCTION MAIN MOD = 7-Speed Transmissions only

Foldout 13. 4000 Product Family Hydraulic Schematic—Neutral

COOLER/LUBE EX. BACKFILL CONVERTER C5 V09253.00.00

4K Service Manual 4th Gen SM4014EN 200510

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