3K Service Manual 4th Gen SM4013EN 200906

SERVICE MANUAL

3000 PRODUCT FAMILY ALLISON 4th GENERA GENERATION TION CONTROLS

SM4013EN

SERVICE MANUAL ALLISON 4th GENERATION CONTROLS

3000 PRODUCT FAMILY

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M A N U A L — 3 0 0 0 P r o d u c t F a m i l y — A l l i s o n 4 t h G e n e r a t i o n C o n t r o ls — V O C A T IO N A L M O D E L S

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T h e f o l lo w in g t r a d e m a r k s a r e t h e p r o p e r t y o f t h e c o m p a n i e s in d i c a t e d : • A l l i s o n D i a g n o s t i c O p t i m i z e d C o n n e c t i o n ® ( A l l i s o n D O C ® ) i s a t r a d e m a r k o f A l l i s o n T r a n s m i s s i o n I n c . • B i o b o r ® J F i s t h e r e g i s t e r e d t r a d e m a r k f o r a b i o l o g i c a l i n h i b i t o r m a n u f a c t u r e d b y H a m m o n d s F u e l A d d i t i v e s C o m p a n y . • D E X R O N ® i s a r e g i s t e r e d t r a d e m a r k o f A l l i s o n T r a n s m i s s i o n I n c . . • S p i r a l o c k ® i s a r e g i s t e r e d t r a d e m a r k o f S p i r a l o c k o f M i c h i g a n . • T e fl o n ® i s a r e g i s t e r e d t r a d e m a r k o f t h e D u P o n t C o r p o r a t i o n . • T r a n S y n d T M i s a t r a d e m a r k o f C a s t r o l , L t d . • V i t o n T M i s a t r a d e m a r k o f D u P o n t C o r p o r a t i o n .

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E S P O N S I B I L I T Y t o b e c o m p l e t e l y f a m i l i a r w i t h t h e w a r n i n g s a n d c a u t i o n s i n t h i s m a n u a l . g s a n d c a u t io n s a d v is e o f s p e c i fi c m e t h o d s o r a c t io n s t h a t c a n r e s u l t in p e r s o n a l i n ju r y , m a g e , o r c a u s e t h e e q u ip m e n t t o b e c o m e u n s a f e . T h e s e w a r n in g s a n d c a u t i o n s a r e n o t llis o n T r a n s m is s io n c o u ld n o t p o s s ib l y k n o w , e v a lu a t e , o r a d v i s e t h e s e r v ic e t r a d e o f a l l r o c e d u r e s b y w h i c h s e r v ic e m ig h t b e p e r f o r m e d o r o f t h e p o s s ib l e h a z a r d o u s c o n s e q u e n c e s d u r e . C o n s e q u e n t ly , A llis o n T r a n s m is s io n h a s n o t u n d e r t a k e n a n y s u c h b r o a d e v a l u a t io n . N Y O N E W H O U S E S A S E R V I C E P R O C E D U R E O R T O O L W H I C H I S N O T R E C O M M E N D E D T R A N S M I S S I O N M U S T fi r s t b e t h o r o u g h ly s a tis fi e d t h a t n e it h e r p e r s o n a l s a fe t y n o r e q u i p m e n t je o p a r d i z e d b y t h e s e r v ic e m e t h o d s u s e d .

e r s e r v ic e a n d e d u re s re c o m m u a l a r e e f fe c t iv g s p e c ia lly d e s

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e n t . T h e s e r v i c e d e s c r i b e d i n t h i s p r o c e d u r e s r e q u i r e e d .

N S , a n d N O T E S i n t h i s m a n u a l a p p ly o n l y t o t h e A l l i s o n t r a n s m i s s io n a n d n o t h i c h m a y i n t e r a c t w i t h t h e t r a n s m i s s io n . B e s u r e t o r e v i e w a n d o b s e r v e a n y p r o v i d e d b y t h e v e h i c l e m a n u f a c t u r e r a n d / o r b o d y b u i l d e r a t a l l t i m e s t h e A l l i s o n i c e d .

W A R N IN G S , C A U T IO N S , N O T E S T h r e e t y p e s o f h e a d i n g s a r e u s e d i n t h i s m a n u a l t o a t t r a c t y o u r a t t e n t i o n : W A R N I N G : A w a r n i n g i s u s e d w h e n a n o p e r a t i n g p r o c e d u r e , p r a c t i c e , e t c . , w h i c h , i f n o t c o r r e c t l y f o l l o w e d , c o u l d r e s u l t i n p e r s o n a l i n ju r y o r l o s s o f l i f e .

C A U T I O N : A c a u t i o n i s u s e d w h e n a n o p e r a t i n g p r o c e d u r e , p r a c t i c e , e t c . , w h i c h , i f n o t s t r i c t l y o b s e r v e d , c o u l d r e s u l t i n d a m a g e t o o r d e s t r u c t io n o f e q u ip m e n t .

N O T E : A n o t e i s u s e d w h e n a n o p e r a t i n g p r o c e d u r e , p r a c t i c e , e t c . , i s e s s e n t i a l t o h i g h l i g h t .

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• T o h e l p p r e v e n t p e r s o n a l in j u r y o r p r o p e r t y d a m a g e c a u s e d b y s u d d e n a n d u n e x p e c t e d v e h ic l e m o v e m e n t , d o n o t c h e c k t h e fl u i d u n t i l y o u : • P u t t h e t r a n s m is s io n in N

(N e u t r a l)…

a n d

• A p p l y t h e p a r k in g b r a k e a n d e m e r g e n c y b r a k e s a n d m a k e s u r e t h e y a r e p r o p e r l y e n g a g e d … a n d • C h o c k t h e w h e e ls a n d t a k e a n y o t h e r s t e p s n e c e s s a r y t o k e e p t h e v e h i c le f r o m m o v i n g . • A v o i d c o n t a c t w i t h t h e h o t fl u i d o r t h e s u m p w h e n d r a in i n g t r a n s m i s s io n fl u i d . D i r e c t c o n t a c t w i t h t h e h o t fl u i d o r t h e h o t s u m p m a y r e s u l t i n b o d i l y i n j u r y . • T a m t t a c d c c

o h e lp a v o id p e r s o n a l in ju r y , s u c h a s b u r n s v o id e q u i p m e n t d a m a g e , d o n o t s ta ll th e t o a x im u m a n d m o n it o r t r a n s m is s io n fl u id t e o id l e if c o n v e r te r o u t (to c o o le r ) te m p e r a tu r a n s m is s io n a t h ig h e n g in e p o w e r a t t r a n s m r a p id r is e in th e tr a n s m is s io n fl u id te m p e r o n v e r t e r is a b s o r b in g a ll o f th e e n g i n e p o w i s s ip a te th e e x c e s s i v e h e a t lo a d . E x t e n d e d a u s e s tr a n s m is s io n a n d c o o lin g s y s te m d a a u s i n g l e a k i n g h i g h t e m p e r a t u r e fl u i d .

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, f r o m h o t t r a n s m is s io r q u e c o n v e rte r f o r m o m p e r a tu r e . Im m e d ia te re e x c e e d s 1 5 0 ° C (3 0 0 is s io n s ta ll o r n e a r s t a tu r e . T h e fl u id in th e e r a n d th e v e h ic le c o o o p e r a tio n u n d e r h ig h m a g e , a n d c a n p o s s ib

n fl u id r e th a n ly r e tu r ° F ). O p a ll c o n d tra n s m l in g s y h e a t lo ly fa il h

a n d /o r te n s e n th e e e r a tin g itio n s is s io n s te m c a d c o n y d ra u l

t o h e l p c o n d s n g i n e t h e c a u s e s t o r q u e a n n o t d i t i o n s i c l i n e s

d e q u i p m e n t d a m a g e w h i l e c o n d u c t i n g a t r a n s m i s s i o n s i t i v e l y p r e v e n t e d f r o m m o v i n g . A p p l y t h e p a r k i n g o c k t h e w h e e l s s e c u r e l y . W a r n p e r s o n n e l t o k e e p l p a t h .

• T o h e l p a v o i d p e r s o n a l i n j u r y a n d / o r e q u i p m e n t d a m a g e , a d r i v i n g t r a n s m i s s i o n s t a l l t e s t m u s t b e p e r f o r m e d b y a t r a i n e d d r i v e r a n d a q u a l i fi e d t e c h n i c i a n . • U s e a p p r o p r i a t e s a f e t y e q u i p m e n t s u c h a s s a f e t y g l a s s e s , s a f e t y s h o e s , a n d g l o v e s . • D o n o t b u r n d i s c a r d e d T e fl o n ® s e a l s ; t o x i c g a s e s a r e p r o d u c e d b y b u r n i n g T e fl o n ® . • N e v e r d r y b e a r i n g s b y s p i n n i n g t h e m w i t h c o m p r e s s e d a ir . A s p i n n i n g b e a r i n g c a n d i s i n t e g r a t e , a l l o w i n g b a l l s o r r o l l e r s t o b e c o m e l e t h a l fl y i n g p r o j e c t i l e s . A l s o , s p i n n i n g a b e a r i n g w i t h o u t l u b r i c a t i o n c a n d a m a g e t h e b e a r i n g . • A v o i d c o n t a c t w i t h t h e h o t fl u i d o r t h e s u m p w h e n d r a in i n g t r a n s m i s s io n fl u i d . D i r e c t c o n t a c t w i t h t h e h o t fl u i d o r t h e h o t s u m p m a y r e s u l t i n b o d i l y i n j u r y .

i v

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2 4 3 k g ( 5 3 5 lb )

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2 6 1 k g (5 7 5 lb )

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a t r a n s m i s s i o n

• T o h e l p a v o i d p e r s o n a l i n j u r y , s e c u r e l y s u p p o r t t h e c o o l e r b e f o r e r e m o v i n g t h e b o l t s r e t a i n i n g t h e c o o l e r t o t h e m a n i f o l d . T h e c o o l e r w e i g h s 2 9 k g ( 6 4 l b ) ; u s e c a r e w h e n h a n d l i n g t h e c o o l e r . • T h e t r a n s f e r c a s e m o d u l e a s s e m b l y w e ig h s a p p r o x i m a t e ly 2 7 0 k g ( 5 9 5 l b ) . • T h e c o n t r o l v a l v e m o d u l e a s s e m b l y w e ig h s a p p r o x i m a t e ly 2 5 k g ( 5 6 l b ) . H a n d l e c a r e f u l l y t o a v o i d p e r s o n a l i n j u r y o r c o n t r o l v a l v e m o d u l e d a m a g e . T h e c o n t r o l v a l v e m o d u l e a s s e m b l y u s e d i n a 3 7 0 0 S P w e ig h s a p p r o x im a t e ly 2 9 k g ( 6 5 l b ) . • T h e r e t a r d e r m o d u l e a s s e m b l y w e ig h s a p p r o x i m a t e l y 6 4 k g ( 1 4 1 l b ) . U s e c a r e t o p r e v e n t i n j u r y t o p e r s o n n e l w h i l e h a n d l i n g t h e r e t a r d e r m o d u l e a s s e m b l y . • P i s t o n s p r i n g s a r e h i g h l y c o m p r e s s e d . B e e x t r e m e l y c a r e f u l d u r i n g d i s a s s e m b l y . P e r s o n a l i n j u r y c a n o c c u r i f t h e s p r i n g f o r c e i s n o t c o n t r o l l e d . • P i s t o n s p r i n g s a r e h i g h l y c o m p r e s s e d . B e e x t r e m e l y c a r e f u l d u r i n g r e m o v a l a n d i n s t a l l a t i o n . P e r s o n a l i n j u r y c a n o c c u r i f t h e s p r i n g f o r c e i s n o t c o n t r o l l e d . • P is t o n s p r in g s a r e h i g h ly c o m p r e s s e d . B e e x t r e m e ly c a r e f u l d u r in g P e r s o n a l i n j u r y c a n o c c u r i f t h e s p r i n g f o r c e i s n o t c o n t r o l l e d .

i n s t a l l a t i o n .

• P i s t o n s p r i n g s a r e h i g h l y c o m p r e s s e d . B e e x t r e m e l y c a r e f u l d u r i n g r e m o v a l . P e r s o n a l i n j u r y c a n o c c u r i f t h e s p r i n g f o r c e i s n o t c o n t r o l l e d . • P is t o n s p r in g s a r e h i g h ly c o m p r e s s e d . B e e x t r e m e ly c a r e f u l d u r in g P e r s o n a l i n j u r y c a n o c c u r i f t h e s p r i n g f o r c e i s n o t c o n t r o l l e d .

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2 0 0 9


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• S p r i n g s ( 1 0 8 ) a n d ( 1 1 2 ) a r e h i g h l y c o m p r e s s e d . B e e x t r e m e l y c a r e f u l d u r i n g d i s a s s e m b l y . P e r s o n a l i n j u r y c a n o c c u r i f t h e s p r i n g f o r c e i s n o t c o n t r o l l e d . • T h e r e t a r d e r m o d u l e a s s e m b l y w e ig h s a p p r o x i m a t e ly 6 4 k g ( 1 4 1 l b ) . U s e c a r e t o p r e v e n t i n j u r y t o p e r s o n n e l w h i l e h a n d l i n g t h e r e t a r d e r m o d u l e a s s e m b l y . • T h e t r a n s f e r c a s e m o d u l e a s s e m b l y w e ig h t s a p p r o x i m a t e l y 2 7 0 k g ( 5 9 5 l b ) . • T r a n s m i s s i o n s i n s t a l l e d i n o v e r h a u l s t a n d s m u s t b e p o s i t i o n e d v e r t i c a l l y b e f o r e i n s t a l l i n g c o n t r o l v a l v e m o d u l e . F a i l u r e t o d o s o c o u l d r e s u l t i n p e r s o n a l i n j u r y . • T h e c o n t r o l v a l v e m o d u l e a s s e m b l y w e i g h s a p p r o x i m a t e ly 2 5 k g ( 5 6 l b ) . H a n d l e c a r e f u l l y t o a v o i d p e r s o n a l i n j u r y o r c o n t r o l v a l v e m o d u l e d a m a g e . T h e c o n t r o l v a l v e m o d u l e a s s e m b l y u s e d i n a 3 7 0 0 S P w e ig h s a p p r o x im a t e ly 2 9 k g ( 6 5 l b ) . • T o h e l p a v o i d p e r s o n a l i n j u r y , s e c u r e l y s u p p o r t t h e c o o l e r i n i t s i n s t a l l e d p o s i t i o n b e f o r e i n s t a l l i n g t h e b o l t s r e t a i n i n g t h e c o o l e r t o t h e m a n i f o l d . T h e c o o l e r w e i g h s 1 4 0 k g ( 6 4 l b ) , u s e c a r e w h e n h a n d l i n g t h e c o o l e r . • T r a n s m i s s i o n d r y w e i g h t s a r e a s f o l l o w s : • B a s e tr a n s m is s io n — • W ith R e ta r d e r — • W ith P T O

2 4 3 k g ( 5 3 5 l b s )

2 7 9 k g ( 6 1 5 l b s )

p r o v is io n —

• W ith R e ta rd e r a n d P T O

2 6 1 k g ( 5 7 5 lb s ) p r o v is io n —

2 9 7 k g ( 6 5 5 l b s )

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5 3 0 k g ( 1 1 7 0 lb s )

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S C O P E O F M A N U A L

. . . . . . . . . . . . . . .1 - 1

a . C o n t e n t a n d O r g a n iz a t io n

P R E S E R V A T I O N A N D a .

. . . . . . . . . . 1 - 1

S T O R A G E

. . . . . . 1 -1 1

P r e s e r v a t i o n M M e t h o d s . . . . . . . . . . . . 1 - 1 1

b . I llu s tr a t io n s . . . . . . . . . . . . . . . . . . . . 1 - 1

b . S t o r a g e ( N e w T r a n s m i s s i o n s , B e f o r e I n s t a l l a t i o n ) . . . . . . . . . . . . . . . . . . . . 1 - 1 1

c . M a in t e n a n c e I n f o r m a t io n . . . . . . . . . . . 1 - 1

c .

1 -2 .

S U P P L E M E N T A R Y I N F O R M A T I O N

d . O n e Y e a r S t o r a g e ( W i t h F l u i d ) . . . . . . . 1 - 1 2

1 -3 .

O R D E R IN G

P A R T S

. . . . . .1 - 6

. . . . . . . . . . . . . . . .1 - 6

a .

T r a n s m i s s i o n N a m e p l a t e . . . . . . . . . . . 1 - 6

b .

P a r t s C a t a l o g . . . . . . . . . . . . . . . . . . 1 - 6

1 -9 .

O n e Y e a r S t o r a g e ( W i t h o u t F l u i d ) . . . . . 1 - 1 1

R E S T O R I N G T R A N S M I S S I O N T O S E R V I C E . . . . . . . . . . . . . . . . . . . . . . 1 - 1 2 a . T r a n s m is s io n E x te r io r . . . . . . . . . . . . 1 - 1 2 b . S e a le d B r e a t h e r a n d O p e n in g s . . . . . . 1 - 1 2

1 -4 .

G E N E R A L D E S C R I P T I O N

. . . . . . . . . . . . 1 - 6

c .

a . M a j o r M o d u l e s . . . . . . . . . . . . . . . . . . 1 - 6

M A J O R

M O D U L E S . . . . . . . . . . . . . . . . .1 - 7

. . . . . . . . . . . . . 1 - 1 2

d . S t o r e d W it h o u t F lu id . . . . . . . . . . . . . 1 - 1 2

b . G e n e r a l F e a t u r e s . . . . . . . . . . . . . . . . 1 - 6 1 -5 .

N e w T r a n s m is s io n s

e . S t o r e d W i t h F l u i d . . . . . . . . . . . . . . . 1 - 1 2 1 -1 0 . O P E R A T IN G

I N S T R U C T I O N S

. . . . . . . . 1 - 1 3

a . I n p u t M o d u le . . . . . . . . . . . . . . . . . . . 1 - 7 b . T o r q u e C o n v e r t e r . . . . . . . . . . . . . . . . 1 - 7 c . P o w e r T a k e o ff ( P T O ) P r o v is io n d . M a in H o u s i n g a n d G e a r M o d u le

. . . . . . . 1 - 7

G e a r i n g R a t i o s

. . . . . . . . . . . . . . . . . 1 - 7

g . C o n t r o l S y s t e m a n d T r a n s m i s s i o n C o n t r o l M o d u l e ( T C M ) . . . . . . . . . . . . . 1 - 7

1 -6 .

D A T A . . . . . . . . . 1 - 1 3

E L E C T R O M A G N E T I C / R A D I O F R E Q U E N C Y I N T E R F E R E N C E . . . . . . . 1 - 1 4

S e c tio n 2 .

P R E V E N T I V E M A I N T E N A N C E

2 -1 .

S C O P E

. . . . . . . . . . . . . . . . . . . . . . . . 2 -1

2 -2 .

P r o g n o s t i c s . . . . . . . . . . . . . . . . . . . . . . 2 - 1

h .

O i l F i l t e r s . . . . . . . . . . . . . . . . . . . . . 1 - 8

a . O i l L i f e M o n i t o r . . . . . . . . . . . . . . . . . 2 - 1

i.

T r a n s m i s s i o n F l u i d C o o l e r s

b .

j .

O u t p u t C o n fi g u r a t i o n . . . . . . . . . . . . . . 1 - 8

M O D E L D E S I G N A T I O N a .

1 -7 .

1 -1 2 .

. . . . . . 1 -7

e . R a n g e C lu tc h e s . . . . . . . . . . . . . . . . . 1 -7 f.

1 - 1 1 . S P E C I F I C A T I O N S A N D

C O D E

. . . . . . . . . 1 - 8

D I A G N O S T IC S

. . . . . . . . . . . . . . . . . . . 1 - 9

d . 2 -3 .

P E R IO D IC a .

I N S P E C T I O N

. . . . . . . . . . . . . 2 - 1 A N D

C A R E . . . . . 2 - 2

E x t e r i o r C l e a n i n g a n d I n s p e c t i o n . . . . . . 2 - 2

I M P O R T A N C E O F P R O P E R F L U I D L E V E L . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 2

T R A N S L i g h t . . . . . . . . . . . . . 1 - 9

a . T r a n s m i s s i o n F l u i d . . . . . . . . . . . . . . . 2 - 2

c . E n te r in g D ia g n o s tic M o d e

2 -4 .

S h i f t S e l e c t o r D i s p l a y

. . . . . . . . . . . . . . . . . 1 - 9

a . B e f o r e S ta r tin g b . C H E C K

c . T r a n s m i s s i o n H e a l t h . . . . . . . . . . . . . . 2 - 1

. . . . . . . . .1 - 8

3 0 0 0 P r o d u c t F a m ily V o c a t io n a l M o d e l S t a n d a r d a n d O p t io n a l F e a t u r e s . . . . . . 1 - 8

F i l t e r L i f e M o n i t o r . . . . . . . . . . . . . . . . 2 - 1

. . . . . . . . . . 1 - 9

d . D ia g n o s tic T r o u b le C o d e s ( D T C s ) . . . . 1 - 1 0

C o p y r ig h t ©

2 0 0 9

b . O i l L e v e l S e n s o r 2 -5 .

T R A N S M IS S IO N


. . . . . . . . . . . . . . . . 2 -2

F L U I D

C H E C K

. . . . . . . .2 - 2 v i i


S E R V IC E

a . E le c tr o n ic C h e c k P r o c e d u r e . . . . . . . . . 2 - 2 F lu i d L e v e l D is p la y C r it e r ia . . . . . . . . . . 2 - 2

C o m p a r in g R e c o r d e d D a t a t o S p e c ifi c a tio n s . . . . . . . . . . . . . . . . . 2 - 1 2

M A N U A L F L U ID L E V E L C H E C K P R O C E D U R E . . . . . . . . . . . . . . . . . . . . 2 - 4

2 - 1 6 . T R A N S M IS S I O N S T A L L T E S T A N D N E U T R A L C O O L -D O W N C H E C K . . . . . . 2 -1 6

b . 2 -6 .

a .

c .

a . P u r p o s e . . . . . . . . . . . . . . . . . . . . . 2 - 1 6

P r e p a r a t i o n . . . . . . . . . . . . . . . . . . . . 2 - 4

b . S t a l l T e s t i n g P P r e p a r a t i o n

b . C o n s i s t e n c y o f R e a d i n g s . . . . . . . . . . . 2 - 4 2 -7 .

c . P e r f o r m i n g a T r a n s m i s s i o n S t a l l T e s t . . 2 - 1 6

C O L D C H E C K ( F ig u r e 2 – 1 ) . . . . . . . . . . . 2 -4 a . P u r p o s e . . . . . . . . . . . . . . . . . . . . . . 2 -4 b . C o ld C h e c k P r o c e d u r e

2 -8 .

2 -9 .

. . . . . . . . . . . . 2 -4

H O T C H E C K ( F ig u r e 2 – 1 ) . . . . . . . . . . . . 2 -4 a . H o t C h e c k P r o c e d u re

. . . . . . . . . . . . . 2 -5

K E E P IN G

. . . . . . . . . . . . . 2 - 5

F L U ID

C L E A N

d .

D r i v i n g T r a n s m i s s i o n S t a l l T e s t . . . . . . 2 - 1 7

e .

D r i v i n g T r a n s m i s s i o n S t a l l T e s t i n g P r e p a r a t i o n . . . . . . . . . . . . . . . . . . . 2 - 1 7

f.

P e r f o r m in g A D r iv in g T r a n s m is s io n S t a l l T e s t . . . . . . . . . . . . . . . . . . . . . . . . 2 -1 8

g . N e u t r a l C o o l D o w n C h e c k P r o c e d u r e h .

2 -1 0 . F L U ID

T r a n s m i s s i o n S t a l l l T e s t R e s u l t s . . . . . . 2 - 1 8

2 -1 7 . F L U ID . . 2 - 6

a .

F l u i d A n d F i l t e r C h a n g e s . . . . . . . . . . . 2 - 6

F l u id A n a ly s i s

L E A K D IA G N O S IS

F i n d i n g t h e L e a k

. . . . . . . . . . . 2 -1 9

. . . . . . . . . . . . . . . 2 -1 9

b . P o w d e r M e th o d . . . . . . . . . . . . . . . . 2 -1 9

b . H i g h C a p a c i t y F i l t e r s . . . . . . . . . . . . . . 2 - 6 c .

. . 2 - 1 8

R E C O M M E N D A T I O N S . . . . . . . . . . 2 - 5

2 - 1 1 . F L U I D A N D F I L T E R C H A N G E I N T E R V A L a .

. . . . . . . . . . 2 - 1 6

c .

. . . . . . . . . . . . . . . . . . 2 - 8

B la c k L ig h t a n d D y e M e t h o d . . . . . . . . 2 - 1 9

C O N T A M I N A T IO N . . . . . . . . . . . . . 2 -8

d . P o s s ib l e P o i n t s o f F l u i d L e a k s a n d T h e ir C a u s e s . . . . . . . . . . . . . . . . . . 2 - 1 9

a . W a te r . . . . . . . . . . . . . . . . . . . . . . . 2 - 8

e . R e p a ir in g t h e L e a k . . . . . . . . . . . . . . 2 - 2 0

b . E n g in e C o o l a n t . . . . . . . . . . . . . . . . . 2 - 8

2 - 1 8 . O U T P U T F L A N G E /Y O K E A N D O IL S E A L M A I N T E N A N C E ( A ll, E x c e p t 3 7 0 0 S P ) . . . 2 - 2 0

2 -1 2 . F L U ID

c .

M e ta l . . . . . . . . . . . . . . . . . . . . . . . . 2 -8

a .

2 - 1 3 . F L U I D A N D F IL T E R C H A N G E P R O C E D U R E . . . . . . . . . . . . . . . . . . . . 2 -8 a . D r a in F lu id

. . . . . . . . . . . . . . . . . . . . 2 - 9

b . R e p l a c e F i l t e r s ( F i g u r e 2 – 2 ) . . . . . . . . . 2 - 9 c .

b . A s s e m b ly . . . . . . . . . . . . . . . . . . . . 2 - 2 1 2 - 1 9 . Y O K E A N D O I L S E A L M A I N T E N A N C E ( 3 7 0 0 S P ) . . . . . . . . . . . . . . . . . . . . . . 2 - 2 1

R e p l a c e F i l t e r s — 3 7 0 0 S P T r a n s m i s s i o n ( F i g u r e 2 – 3 ) . . . . . . . . . . . . . . . . . . . 2 - 9

d . R e fi ll T r a n s m is s io n . . . . . . . . . . . . . . 2 - 1 0

D i s a s s e m b l y ( F i g u r e 2 – 5 ) . . . . . . . . . . 2 - 2 0

a .

D i s a s s e m b l y ( F i g u r e 2 – 6 ) . . . . . . . . . . 2 - 2 1

b . A s s e m b l y ( F i g u r e 2 – 6 ) . . . . . . . . . . . 2 - 2 2 2 - 2 0 . O N - V E H I C L E M A I N T E N A N C E

. . . . . . . . 2 - 2 2

2 -1 4 . B R E A T H E R . . . . . . . . . . . . . . . . . . . . . 2 -1 1 a . L o c a tio n a n d P u r p o s e . . . . . . . . . . . . 2 - 1 1

S e c tio n 3 .

b . M a in te n a n c e . . . . . . . . . . . . . . . . . . 2 - 1 1 P R E S S U R E S . . . . . 2 - 1 1

3 -1 .

S C O P E

a . T r a n s m i s s io n a n d V e h i c le P r e p a r a t i o n . . . . . . . . . . . . . . . . . . . 2 - 1 1

3 -2 .

T O O L S A N D E Q U I P M E N T . . . . . . . . . . . . 3 - 1

2 -1 5 . C H E C K IN G

C L U T C H

b . R e c o r d i n g D a t a . . . . . . . . . . . . . . . . 2 - 1 2

v i i i

G E N E R A L O V E R H A U L I N F O R M A T I O N

C o p y r ig h t ©

. . . . . . . . . . . . . . . . . . . . . . . . 3 -1

a . I m p r o v i s e d T o o l s a n d E q u i p m e n t . . . . . . 3 - 1 b .

S p e c i a l T o o l s . . . . . . . . . . . . . . . . . . . 3 - 3


T A B L E c .

3 -3 .

3 -4 .

O F

C O N T E N T S

M e c h a n i c ’s T o o ls a n d S h o p E q u ip m e n t . . . . . . . . . . . . . . . . . . . . 3 - 3

R E P L A C E M E N T P A R T S

g . L ip - T y p e S e a ls . . . . . . . . . . . . . . . . . 3 - 1 7 h . B u t t - J o in t S e a l r in g s . . . . . . . . . . . . . . 3 - 1 7

. . . . . . . . . . . . . 3 - 7

a .

O r d e r i n g I n f o r m a t i o n . . . . . . . . . . . . . . 3 - 7

b .

P a r t s N o r m a l l y R e p l a c e d a t O v e r h a u l . . . 3 - 7

i. 3 -7 .

C A R E F U L H A N D L IN G . . . . . . . . . . . . . . . 3 - 7

B e a r in g s

R E M O V IN G ( O R IN S T A L L IN G ) T R A N S M I S S I O N ( F i g u r e 3 – 1 2 , F i g u r e 3 – 1 3 ) . . . . . . . . . . . . . . . . . . . . 3 - 1 7 a . D r a i n F l u i d

3 -5 .

C L E A N IN G

A N D

I N S P E C T I O N

. . . . . . . . . 3 -7

b .

a . D i r t C a u s e s M a l f u n c t i o n . . . . . . . . . . . . 3 - 7

. . . . . . . . . . . . . . . . . . . 3 - 1 8

D i s c o n n e c t i n g C o n t r o l s . . . . . . . . . . . 3 - 1 9

b . C l e a n i n g P a r t s . . . . . . . . . . . . . . . . . . 3 - 7

c . U n c o u p l i n g F r o m D r i v e l i n e , V e h i c l e , A n d E n g i n e . . . . . . . . . . . . . . . . . . . 3 - 1 9

c . C l e a n i n g B e a r i n g s

d . R e m o v i n g t h e T r a n s m i s s i o n . . . . . . . . 3 - 1 9

. . . . . . . . . . . . . . . 3 - 7

d . K e e p i n g B e a r i n g s C l e a n

3 -6 .

. . . . . . . . . . . . . . . . . . . . 3 -1 7

. . . . . . . . . . . 3 - 7

3 -8 .

W E A R

3 -9 .

S P R IN G

L I M I T S . . . . . . . . . . . . . . . . . . . 3 - 2 0

e .

I n s p e c t i n g B e a r i n g s

. . . . . . . . . . . . . . 3 - 8

f.

I n s p e c t i n g C a s t P a r t s a n d M a c h i n e d S u r f a c e s . . . . . . . . . . . . . . . . . . . . . 3 - 8

3 -1 0 . T O R Q U E S P E C I F IC A T IO N S . . . . . . . . . . 3 - 2 0

g .

I n s p e c t i n g B u s h i n g s a n d T h r u s t W a s h e r s . . . . . . . . . . . . . . . . . . . . . . 3 -9

3 - 1 1 . E N G I N E , T R A N S M I S S I O N A D A P T A T I O N R E Q U I R E M E N T S . . . . . . . . . . . . . . . . . 3 - 2 0

h .

I n s p e c t i n g S e a l r i n g s a n d G a s k e t s

. . . . . 3 - 9

a . M e a s u r i n g E q u i p m e n t . . . . . . . . . . . . 3 - 2 2

i.

I n s p e c t i n g G e a r s . . . . . . . . . . . . . . . . 3 - 9

j .

I n s p e c t i n g S p l i n e d P a r t s

b . F l y w h e e l H o u s i n g P i l o t B o r e D ia m e te r . . . . . . . . . . . . . . . . . . . . 3 - 2 2

k .

I n s p e c t i n g T h r e a d e d P a r t s . . . . . . . . . 3 - 1 0

c .

l.

I n s p e c t i n g R e t a i n i n g R i n g s . . . . . . . . . 3 - 1 0

d . F l y w h e e l H o u s i n g F a c e S q u a r e n e s s . . . 3 - 2 2

m . I n s p e c t i n g S p r i n g s . . . . . . . . . . . . . . 3 - 1 0

e . C r a n k s h a f t H u b P i l o t o r A d a p t e r D ia m e te r . . . . . . . . . . . . . . . . . . . . 3 - 2 2

. . . . . . . . . . 3 - 1 0

S P E C I F I C A T I O N S

. . . . . . . . . . 3 - 2 0

F l y w h e e l H o u s i n g B o r e R u n o u t . . . . . . 3 - 2 2

n .

I n s p e c t i n g C l u u t c h P l a t e s ( F i g u r e 3 – 5 ) . . 3 - 1 0

o .

I n s p e c t i n g S w a g e d a n d I n t e r f e r e n c e - F i t P a r ts . . . . . . . . . . . . . . . . . . . . . . . 3 -1 0

f.

p .

I n s p e c t i n g R e t a i n e r a n d B a l l A s s e m b l y in R e t a r d e r S t a t o r . . . . . . . . . . . . . . . 3 - 1 0

g . C r a n k s h a f t H u b P i l o t o r A d a p t e r C o n c e n t r i c it y . . . . . . . . . . . . . . . . . . 3 - 2 2

q .

I n s p e c t i n g S e a l i n g S u r f a c e s . . . . . . . . 3 - 1 0

h . F l e x p la t e B o l t H o l e F l a t n e s s . . . . . . . . 3 - 2 2

r.

I n s p e c t i n g E l e e c t r i c a l C o m p o n e n t s

i.

. . . . 3 - 1 1

A S S E M B L Y P R O C E D U R E S . . . . . . . . . . 3 - 1 6 a .

P a r t s L u b r i c a t i o n

. . . . . . . . . . . . . . . 3 - 1 6

b . G r e a s e U s e d f o r A s s e m b l y . . . . . . . . . 3 - 1 6 c . S e a l i n g C o m p o u n d s a n d N o n s o l u b l e G r e a s e s . . . . . . . . . . . . . . . . . . . . . 3 - 1 6 d . C lu tc h e s a n d P is t o n s

. . . . . . . . . . . . 3 - 1 6

e . T h r e a d e d P lu g s a n d H y d r a u lic F i t t i n g s . . . . . . . . . . . . . . . . . . . . . . 3 - 1 7 f.

C r a n k s h a f t H u b P i l o t o r A d a p t e r S q u a r e n e s s . . . . . . . . . . . . . . . . . . 3 - 2 2

T o r q u e C o n v e r t e r A x i a l L o c a t i o n

. . . . . 3 - 2 2

3 - 1 2 . C H E C K I N G F L E X P L A T E D R I V E A S S E M B L Y . . . . . . . . . . . . . . . . . . . . . 3 - 2 3 a . F l e x p la t e I n s p e c t i o n

. . . . . . . . . . . . . 3 - 2 3

b . E n g i n e C r a n k s h a f t E n d P l a y . . . . . . . . 3 - 2 3 c .

F l e x p l a t e A s s e m b l y I n s t a l l a t i o n

. . . . . . 3 - 2 3

3 - 1 3 . C H A S S I S A N D D R I V E L I N E I N S P E C T I O N . . . . . . . . . . . . . . . . . . . . 3 - 2 3

C o a t e d T h r e a d e d F a s t e n e r s . . . . . . . . 3 - 1 7

C o p y r ig h t ©

2 0 0 9


i x

S E R V IC E

S e c tio n 4 .

4 -1 .

S C O P E


T R A N S M I S S I O N D IS A S S E M B L Y . . . . . . . . . . . . . . . . . . . . . . . . 4 - 1

a . S e c tio n

. . . . . . . . . . . . . . . . . . . . . . 4 -1

b . P r o c e d u r e s . . . . . . . . . . . . . . . . . . . . 4 - 1 c .

q . R e m o v a l o f C 3 / C 4 C lu t c h A s s e m b ly F r o m M a in H o u s in g M o d u le ( F ig u r e 4 – 1 7 ) . . . . . . . . . . . . . . . . . 4 - 1 1

I l l u s t r a t i o n s . . . . . . . . . . . . . . . . . . . . 4 - 1

d . G e n e r a l I n f o r m a t i o n

S e c t i o n 5 . 5 -1 .

D IS A S S E M B L Y O F T R A N S M IS S IO N

. . . . . . . . . . . . . . . . . . . . . . . . 5 - 1 . . . . . . . . . . . . . . . . . . . . . . 5 -1

b . P r o c e d u r e s . . . . . . . . . . . . . . . . . . . . 5 -1 c .

. . . . . 4 - 1

I l l u s t r a t i o n s . . . . . . . . . . . . . . . . . . . . 5 - 1

d . F o ld o u t s . . . . . . . . . . . . . . . . . . . . . . 5 - 1

a . M o u n t in g T r a n s m is s io n o n R e p a ir S t a n d . . . . . . . . . . . . . . . . . . . . . . . 4 -1

5 -2 .

b . R e m o v a l o f C o m m o n E x t e r n a ll y - M o u n t e d P a r t s ( F i g u r e 4 – 2 ) . . . . . . . . . 4 - 2

G E N E R A L I N F O R M A T I O N F O R M O D U L E R E B U IL D . . . . . . . . . . . . . . . . . . . . . . . 5 - 1

5 - - 3 .

T O R Q U E

c .

R e m o v a l o f S p e e d S e n s o rs

. . . . . . . . . 4 -3

e . R e m o v i n g I n t e g r a l R e t a r d e r S u m p O i l C o o le r ( F o l d o u t 1 8 - 2 ) . . . . . . . . . . . . . 4 - 4 f.

5 -4 .

b . D i s a s s e m b l y o f t h e B e a r i n g R e t a i n e r A s s e m b l y . . . . . . . . . . . . . . . . . . . . . 5 - 7 c . D i s a s s e m b l y o f t h e P T O G e a r A s s e m b l y . . . . . . . . . . . . . . . . . . . . . 5 - 7 d . A s s e m b l y o f t h e P T O

R e m o v a l o f T o r q u e C o n v e r t e r M o d u l e e ( F ig u r e 4 – 7 ) . . . . . . . . . . . . . . . . . . . 4 - 7

R e m o v a l o f R e t a r d e r M o d u l e ( F o l d o u t 1 1 A a n d F i g u r e 4 – 9 ) . . . . . . . . 4 - 8

l.

R e m o v a l o f T r a n s f e r C a s e A d a p te r H o u s in g M o d u l e ( F i g u r e 4 – 1 0 ) . . . . . . . 4 - 9

m . R e m o v a l o f R e a r C o v e r M o d u le ( F ig u r e 4 – 1 1 ) . . . . . . . . . . . . . . . . . . . 4 - 9 n . R e m o v a l o f M a in S h a f t M o d u le ( F ig u r e 4 – 1 2 ) . . . . . . . . . . . . . . . . . 4 - 1 0

f. 5 -5 .

M o d u l e A s s e m b l y . . . . . . . . . . . . . . . . 5 - 8

T O R Q U E C O N V E R T E R H O U S I N G M O D U L E ( M o d e l s W i t h o u t P T O P r o v is io n ) . . . . . . . . . . . . . . . . . . . . . . . 5 - 8 a . D is a s s e m b ly ( F o l d o u t 6 - 1 ) . . . . . . . . . . 5 - 8 b . A s s e m b l y ( F o l d o u t 6 - 1 ) . . . . . . . . . . . . 5 - 8

5 -6 .

F R O N T S U P P O R T A N D C H A R G IN G O I L P U M P M O D U L E . . . . . . . . . . . . . . . . . . . 5 -9 a . M o d u l e D i s a s s e m b l y ( F o l d o u t 7 - 1 ) . . . . . 5 - 9

o . R e m o v a l o f P 2 M o d u l e , C 5 C l u t c h P l a t e s , a n d P 1 M o d u l e ( F i g u r e 4 – 1 3 , F i g u r e 4 – 1 4 ) . . . . . . . . . . . . . . . . . . 4 - 1 0 p . R e m o v a l o f F r o n t S u p p o r t / C h a r g i n g P u m p M o d u le a n d R o t a t in g C lu t c h M o d u le ( F ig u r e 4 – 1 5 , F ig u r e 4 – 1 6 ) . . . . 4 - 1 0

G e a r A s s e m b ly . . . 5 - 7

e . A s s e m b l y o f t h e B e a r i n g R e t a i n e r A s s e m b l y . . . . . . . . . . . . . . . . . . . . . 5 - 8

R e m o v a l o f C o o n v e r t e r H o u s i n g M o d u l e ( F ig u r e 4 – 8 ) . . . . . . . . . . . . . . . . . . . 4 - 8

k .

T O R Q U E C O N V E R T E R H O U S I N G M O D U L E ( M o d e l s W i t h P T O P r o v i s i o n ) . . . . 5 - 7 a . M o d u l e D i s a s s e m b l y ( F o l d o u t 6 - 2 ) . . . . . 5 - 7

R e m o v a l o f P T O ( s ) ( F o l d o u t 1 9 - 2 ) . . . . . 4 - 5

h . R e m o v a l o f C o n t r o l V a l v e M o d u l e ( F i g u r e 4 – 6 ) . . . . . . . . . . . . . . . . . . . 4 - 6

j .

M O D U L E . . . . . . .5 -1

b . A s s e m b l y ( F o l d o u t 5 ) . . . . . . . . . . . . . 5 - 2

g . R e m o v a l o f T r a n s f e r C a s e M o d u l e — 3 7 0 0 S P . . . . . . . . . . . . . . . . . . . . . . 4 - 5

i.

C O N V E R T E R

a . D i s a s s e m b l y ( F o l d o u t 5 ) . . . . . . . . . . . 5 - 1

d . R e m o v a l o f I n n t e g r a l O i l C o o l e r ( F o ld o u t 1 8 - 1 ) . . . . . . . . . . . . . . . . . . 4 - 3

x

S C O P E

a . S e c t io n

. . . . . . . . . . . . . . 4 - 1

e . F o l d o u t s . . . . . . . . . . . . . . . . . . . . . . 4 - 1 4 -2 .

M O D U L E R E B U I L D

b . A s s e m b l y o f t h e F r o n t S u p p o r t . . . . . . 5 - 1 2 c .

5 -7 .

A s s e m b l y o f t h e P u m p H o u s i n g ( F o l d o u t 7 - 1 ) . . . . . . . . . . . . . . . . . . 5 - 1 3

R O T A T I N G C L U T C H

M O D U L E

. . . . . . . . 5 - 1 5

a . D i s a s s e m b l y ( F o l d d o u t 7 - 2 ) . . . . . . . . . 5 - 1 5

C o p y r i g h t © 2 0 0 9 A l l i s o n T r a n s m i s s i o n , I n c .

T A B L E

O F

b . A s s e m b ly ( F o ld o u t 7 - 2 ) . . . . . . . . . . . 5 - 2 0 5 -8 .

C 3 /C 4 A N D

M A IN

H O U S IN G

C O N T E N T S h .

M O D U L E . . . 5 - 2 2

A s s e m b l y a n d I n s t a l l a t i o n o f R e t a r d e r C o n t r o l B o d y A s s e m b l y ( F o ld o u t 1 1 A ) . . . . . . . . . . . . . . . . . 5 - 3 8

a . D i s a s s e m b l y ( F o l d o u t 8 - 1 ) . . . . . . . . . 5 - 2 2 b . A s s e m b l y ( F o l d o u t 8 - 1 ) . . . . . . . . . . . 5 - 2 3

5 -1 3 . R E A R

C O V E R

M O D U L E

. . . . . . . . . . . . 5 - 3 8

a . D i s a s s e m b l y ( F o l d o u t 1 1 B ) . . . . . . . . . 5 - 3 8 5 -9 .

M A IN

S H A F T M O D U L E . . . . . . . . . . . . . 5 - 2 5

a . D i s a s s e m b l y ( 3 0 0 0 P r o d u c t F a m ily M o d e l s , E x c e p t 3 3 5 0 0 a n d 3 7 0 0 S P M o d e l s ) ( F o l d d o u t 8 - 2 ) . . . . . . . . . . . . 5 - 2 5

b . D i s a s s e m b l y o f t h e P 3 P l a n e t a r y C a r r i e r A s s e m b l y ( F o l d o u t 1 1 B ) . . . . . . . . . . . 5 - 3 9 c . D i s a s s e m b l y o f t h e R e a r C o v e r A s s e m b l y ( F o l d o u t 1 1 B ) . . . . . . . . . . . 5 - 3 9

b . A s s e m b l y ( 3 0 0 0 P r o d u c t F a m i l y M o d e l s , E x c e p t 3 5 0 0 , 3 7 0 0 S P M o d e l s ) ( F o l d o u t 8 - 2 ) . . . . . . . . . . . . . . . . . . 5 - 2 6

d . A s s e m b l y o f R e a r C o v e r ( F o l d o u t 1 1 B ) . . . . . . . . . . . . . . . . . 5 - 4 0

c .

e . A s s e m b l y o f t h e P 3 P l a n e t a r y C a r r i e r A s s e m b l y ( F o l d o u t 1 1 B ) . . . . . . . . . . . 5 - 4 0

M o d u l e D i s a s s e m b l y - ( 3 5 0 0 T r a n s m i s s i o n M o d e l ) ( F o l d o u t 9 - 1 ) . . . . 5 - 2 6

d . M o d u l e A s s e m b l y ( 3 5 0 0 T r a n s m i s s i o n M o d e l ) ( F o l d o u t 9 9 - 1 ) . . . . . . . . . . . . . 5 - 2 6 e . M o d u l e D i s a s s e m b l y ( 3 7 0 0 S P T r a n s m i s s i o n M o d e l ) ( F o l d o u t 9 - 2 ) . . . . 5 - 2 6 f.

M o d u l e A s s e m b l y ( 3 7 0 0 S P T r a n s m i s s io n M o d e l ) ( F o l d o u t 9 - 2 ) . . . . 5 - 2 6

5 - 1 0 . P 1 P L A N E T A R Y

M O D U L E

. . . . . . . . . . . 5 - 2 7

f.

C o m p l e t i o n o f t h e R e a r C o v e r M o d u l e ( F o l d o u t 1 1 B ) . . . . . . . . . . . . . . . . . 5 - 4 3

5 - 1 4 . A D A P T E R H O U S I N G A N D P 3 O V E R H A U L . . . . . . . . . . . . . . . . . . . . 5 - 4 5 a . D i s a s s e m b l y ( F o l d o u t 1 7 - 2 ) . . . . . . . . 5 - 4 5 b . A s s e m b ly ( F o ld o u t 1 7 - 2 ) . . . . . . . . . . 5 - 4 6 5 - 1 5 . S C A V E N G E P U M P O V E R H A U L

. . . . . . . 5 - 4 7

a . D is a s s e m b ly ( F o l d o u t 1 0 - 1 ) . . . . . . . . 5 - 2 7

a . D is a s s e m b ly ( F o l d o u t 1 9 - 1 ) . . . . . . . . 5 - 4 7

b . A s s e m b ly ( F o ld o u t 1 0 - 1 ) . . . . . . . . . . 5 - 2 7

b . A s s e m b ly ( F o ld o u t 1 9 - 1 ) . . . . . . . . . . 5 - 4 9

5 - 1 1 . P 2 P L A N E T A R Y

M O D U L E

. . . . . . . . . . . 5 - 2 9

a . D is a s s e m b ly ( F o l d o u t 1 0 - 2 ) . . . . . . . . 5 - 2 9 b . A s s e m b l y ( F o l d o u t 1 0 - 2 ) . . . . . . . . . . 5 - 2 9 5 -1 2 . R E T A R D E R

M O D U L E . . . . . . . . . . . . . . 5 - 3 1

a . D i s a s s e m b l y o f R e t a r d e r V a l v e B o d y ( F o l d o u t 1 1 A ) . . . . . . . . . . . . . . . . . 5 - 3 1 b . D i s a s s e m b l y o f R e t a r d e r H o u s i n g ( F o l d o u t 1 1 A ) . . . . . . . . . . . . . . . . . 5 - 3 2 c . D i s a s s e m b l y o f P 3 P l a n e t a r y C a r r i e r A s s e m b l y ( F o l d o u t 1 1 A ) . . . . . . . . . . . 5 - 3 2

5 - 1 6 . T R A N S F E R C A S E M O D U L E

. . . . . . . . . 5 - 4 9

a . D is a s s e m b ly o f T r a n s fe r C a s e M o d u le ( F o l d o u t 1 2 - 2 , F o l d o u t 1 3 , F o l d o u t 1 4 ) . . . . . . . . . . . . . . . . . . . 5 - 4 9 b . D i s a s s e m b l y o o f C 6 C l u t c h ( F o l d o u t 1 4 ) . . . . . . . . . . . . . . . . . . 5 - 5 1 c .

A s s e m b l y o f C 6 C l u t c h ( F o l d o u t 1 4 ) . . . 5 - 5 1

d . D i s a s s e m b l y o o f C 7 C l u t c h ( F o l d o u t 1 3 ) . . . . . . . . . . . . . . . . . . 5 - 5 2 e . A s s e m b l y o f C 7 C l u t c h H o u s i n g ( F o l d o u t 1 3 ) . . . . . . . . . . . . . . . . . . 5 - 5 2

d . D i s a s s e m b l y o f R R e t a r d e r S t a t o r A s s e m b l y ( F o l d o u t 1 1 A ) . . . . . . . . . . . 5 - 3 3

f.

e . A s s e m b l y o f R e t a r d e r S t a t o r ( F o l d o u t 1 1 A ) . . . . . . . . . . . . . . . . . 5 - 3 3

g . A s s e m b l y o f O i l P u m p ( F o l d o u t 1 3 )

f.

h . D i s a s s e m b l y o f P P 4 C a r r i e r ( F o l d o u t 1 4 ) . . . . . . . . . . . . . . . . . . 5 - 5 3

A s s e m b ly o f P 3 P la n e t a r y C a r r ie r A s s e m b l y ( F o l d o u t 1 1 A ) . . . . . . . . . . . 5 - 3 4

g . A s s e m b l y o f R e t a r d e r H o u s i n g A s s e m b l y ( F o l d o u t 1 1 A ) . . . . . . . . . . . 5 - 3 5 C o p y r ig h t ©

2 0 0 9

i.

D i s a s s e m b l y o o f O i l P u m p ( F o l d o u t 1 3 ) . . . . . . . . . . . . . . . . . . 5 - 5 3 . . . 5 - 5 3

A s s e m b l y o f P 4 C a r r i e r ( F o l d o u t 1 4 ) . . . 5 - 5 3


x i

S E R V IC E


j .

D i s a s s e m b l y o f D r i v e , I d l e r , a n d D r i v e n G e a r s ( F o ld o u t 1 3 ) . . . . . . . . . . . . . . 5 - 5 4

j .

A s s e m b l y o f C 6 C o n t r o l V a l v e B o d y ( F o l d o u t 1 5 - 1 , F o l d o u t 1 5 - 2 ) . . . . . . . . 5 - 6 4

k .

A s s e m b l y o f D r iv e , I d l e r , a n d D r iv e n G e a r s ( F o ld o u t 1 3 ) . . . . . . . . . . . . . . 5 - 5 4

k . A s s e m b l y o f F i lt e r L i f e V a l v e B o d y ( F ig u r e 5 – 7 3 ) . . . . . . . . . . . . . . . . . 5 - 6 4

l.

D i s a s s e m b l y o f t t h e F r o n t O u t p u u t H o u s i n g a n d F r o n t O u t p u t S h a f t ( F o ld o u t 1 3 ) . . . . . . . . . . . . . . . . . . 5 - 5 4

l.

A s s e m b l y o f t h e S o l e n o i d V a l v e B o d y ( F o l d o u t 1 5 - 1 , F o l d o u t 1 5 - 2 ) . . . . . . . . 5 - 6 4

m . A s s e m b l y o f t h e F r o n t O u t p u t H o u s i n g a n d F r o n t O u t p u t S h a f t ( F o l d o u t 1 3 ) . . . 5 - 5 4

m . I n s t a l l a t i o n o f E l e c t r i c a l C o m p o n e n t s a n d S e n s o r s ( F o l d o u t 1 5 - 1 , F o l d o u t 1 5 - 2 ) . . . . . . . . . . . . . . . . . . 5 - 6 4

n . D i s a s s e m b l y o f t h e R e a r O u t p u t H o u s in g ( F o l d o u t 1 4 ) . . . . . . . . . . . . . 5 - 5 5

n . I n s t a l l a t i o n o f F i l t e r s ( F o l d o u t 1 5 - 1 , F o l d o u t 1 5 - 2 ) . . . . . . . . . . . . . . . . . . 5 - 6 5

o . A s s e m b l y o f t h e R e a r O u t p u t H o u s i n g ( F o ld o u t 1 4 ) . . . . . . . . . . . . . . . . . . 5 - 5 5 p . O u t p u t H o u s i n g B e a r i n g P r e l o a d P r o c e d u r e ( F o l d o u t 1 4 ) . . . . . . . . . . . 5 - 5 6

S e c tio n 6 . 6 - 1 . S C O P E

s .

A S S E M B L Y

. . . . . . . . . . . . . . . . . . . . . . . .6 - 1

a . S e c t io n

q . D i s a s s e m b l y o f C 7 C o n t r o l V a l v e B o d y ( F o ld o u t 1 4 ) . . . . . . . . . . . . . . . . . . 5 - 5 6 r.

T R A N S M I S S I O N

. . . . . . . . . . . . . . . . . . . . . . 6 - 1

b . P r o c e d u r e s . . . . . . . . . . . . . . . . . . . . 6 -1

A s s e m b l y o f C 7 C o n t r o l V a l v e B o d y A s s e m b l y ( F o l d o u t 1 4 ) . . . . . . . . . . . . 5 - 5 6

c .

I l l u s t r a t i o n s . . . . . . . . . . . . . . . . . . . . 6 - 1

d .

G e n e r a l I n f o r m a t i o n

A s s e m b l y o f T T r a n s f e r C a s e M o d u le ( F o l d o u t 1 2 - 2 , F o l d o u t 1 3 , F o ld o u t 1 4 ) . . . . . . . . . . . . . . . . . . . 5 - 5 7

e . F o l d o u t s . . . . . . . . . . . . . . . . . . . . . . 6 - 1 6 -2 .

. . . . . . . . . . . . . . 6 - 1

A S S E M B L Y O F T R A N S M I S S I O N . . . . . . . . 6 - 1 a . A s s e m b l y o f C 3 / C 4 C l u t c h . . . . . . . . . . 6 - 1

5 - 1 7 . C O N T R O L V A L V E M O D U L E ( F o l d o u t 1 5 - 1 , F o ld o u t 1 5 - 2 ) . . . . . . . . . . . . . . . . . . . . 5 - 6 0 a . R e m o v a l o f F ilt e r s

. . . . . . . . . . . . . . 5 - 6 0

b . I n s t a l l a t i o n o f t h e R o t a t i n g C l u t c h M o d u l e ( F i g u r e 6 – 2 ) . . . . . . . . . . . . . . 6 - 1 c .

b . R e m o v a l o f E l e c t r i c a l C o m p o n e n t s a n d S e n s o r s . . . . . . . . . . . . . . . . . . . . . 5 - 6 0 c . D i s a s s e m b l y o f t h e C o n t r o l V a l v e B o d y ( F o l d o u t 1 5 - 1 , F o l d o u t 1 5 - 2 ) . . . . . . . . 5 - 6 1

d . I n s t a l l a t i o n o f t h e P 1 P l a n e t a r y M o d u l e ( F i g u r e 6 – 4 ) . . . . . . . . . . . . . . . . . . . 6 - 2

d . D i s a s s e m b l y o f F i l t e r L i f e V a l v e B o d y ( F ig u r e 5 – 7 3 ) . . . . . . . . . . . . . . . . . 5 - 6 1

e .

I n s t a l l a t i o n o f t h e P 2 P l a n e t a r y M o d u l e ( F i g u r e 6 – 5 ) . . . . . . . . . . . . . . . . . . . 6 - 2

e . D i s a s s e m b l y o f C 6 C o n t r o l V a l v e B o d y ( F o ld o u t 1 5 - 1 , F o l d o u t 1 5 - 2 ) . . . . . . . . 5 - 6 2

f.

I n s t a l l a t io n o f t h e C 5 C lu t c h P a c k ( F i g u r e 6 6 – 5 ) . . . . . . . . . . . . . . . . . . . 6 - 2

f.

g .

I n s t a l l a t io n o f t h e M a i n S h a f t ( F i g u r e 6 – 6 ) . . . . . . . . . . . . . . . . . . . 6 - 3

D i s a s s e m b l y o f C o n t r o l V a l v e B o d y ( F o ld o u t 1 5 - 1 , F o l d o u t 1 5 - 2 ) . . . . . . . . 5 - 6 2

g . D i s a s s e m b l y o f t h e C h a n n e l P l a t e ( F o ld o u t 1 5 - 1 , F o l d o u t 1 5 - 2 ) . . . . . . . . 5 - 6 3 h . A s s e m b l y o f t h e C h a n n e l P l a t e ( F o ld o u t 1 5 - 1 , F o l d o u t 1 5 - 2 ) . . . . . . . . 5 - 6 3 i.

x i i

I n s t a l l a t i o n o f t h e F r o n t S u p p o r t / C h a r g i n g P u m p M o d u l e ( F i g u r e 6 – 3 ) . . . . . . . . . . . . . . . . . . . 6 - 2

A s s e m b l y o f t h e M a i n V a l v e B o d y ( F o l d o u t 1 5 - 1 , F o l d o u t 1 5 - 2 ) . . . . . . . . 5 - 6 3

C o p y r i g h t © 2 0 0 9

h . M a i n S h a f t S e l e c t i v e S h i m M e a s u r e m e n t F o r C l o s e R a t i o M o d e l s ( F i g u r e 6 – 7 ) . . . . . . . . . . . . . . 6 - 3 i.

M a i n S h a f t S e l e c t i v e S h i m M e a s u r e m e n t ( W i i d e R a t i o M o d e l s ) ( F i g u r e 6 – 8 ) . . . . . . . . . . . . . . . . . . . 6 - 4

A l l i s o n T r a n s m i s s io n , I n c .

T A B L E

O F

j .

M a i n S h a f t S e l e c t i v e S h i m M e a s u re m e n t F o r 3 7 0 0 S P ( F ig u r e 6 – 9 ) . . . . . . . . . . . . . . . . . . . 6 - 5

k .

I n s t a l la t i o n R e t a r d e r M o d u l e . . . . . . . . . 6 - 7

l.

I n s t a l la t i o n o f R e a r C o v e r M o d u le ( F i g u r e 6 6 – 1 1 ) . . . . . . . . . . . . . . . . . . . 6 - 8

C O N T E N T S 8 -2 .

F O L D O U T S 1 .

3 0 0 0 P r o d u c t F a m i l y T r a n s m i s s i o n — S e c t i o n

2 .

n . I n s t a l l a t i o n o f T r a n s f e r C a s e M o d u l e ( F ig u r e 6 – 1 3 ) . . . . . . . . . . . . . . . . . . 6 - 9

3 0 0 0 P r o d u c t F a m i l y T r a n s m i s s i o n ( E x c e p t 3 7 0 0 S P ) w i t h P T O P r o v i s i o n a n d R e t a r d e r — C r o s s S e c t i o n

3 .

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p . I n s t a l l a t i o n o f t h e T o r q u e C o n v e r t e r M o d u l e ( F i g u r e 6 – 1 5 ) . . . . . . . . . . . . 6 - 1 0

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p p o r te d w ith a l v ie w s . O v b y lin e d r a w t io n s h ip o f a s , d is a s s e m e m a t ic s a r e e m a n u a l.

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2 . I l l u s t r a t i o n s s h o w c o r r e c t p r o c e d u r e s f o r a l l m o d e l s , i n c l u d i n g m o d e l s n o t i l l u s t r a t e d .

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n c e In l h a s b i z a tio n iz a t io n ia l t o o s c r ib e if t h e


f o r m a t i o n . E a c h t a s k d e s c r i b e d e e n s u c c e s s f u l ly c o m p l e t e d b y s a n d i n d i v i d u a l s . N o t e v e r y o r i n d i v i d u a l p o s s e s s e s t h e l s , t r a i n i n g , o r e x p e r i e n c e t o d t a s k s . H o w e v e r , a n y t a s k m a y f o l lo w in g c o n d i t io n s a r e m e t : 1 - 1

S E R V IC E


1 . T h e o r g a n i z a t i o n o r i n d i v i d u a l h a s t h e r e q u i r e d k n o w le d g e o f t h e t a s k t h r o u g h : • F o r m a l i n s t r u c t i o n a t a n A l l i s o n T r a n s m i s s i o n o r a d i s t r i b u t o r t r a i n i n g f a c i l i t y . • O n - t h e - jo b in s t r u c t i o n b y a n A l l i s o n T r a n s m i s s i o n o r d i s t r i b u t o r r e p r e s e n t a t i v e . • E x p e r ie n c e in p e r f o r m in g t h e t a s k . 2 . T h e w o r k e n v i r o n m e n t is s u it a b l e t o p r e v e n t c o n t a m i n a t i o n o r d a m a g e t o t r a n s m i s s io n p a r t s o r a s s e m b l ie s . 3 . T h e r e q u i r e d t o o l s a n d fi x t u r e s n e e d e d a r e s h o w n i n F i g u r e 3 – 3 a n d T a b le 3 – 1 ( 3 – 2 . T O O L S A N D E Q U I P M E N T o f t h is m a n u a l ) . 4 . R e a s o n a b le a n d p r u d e n t m a in t e n a n c e p r a c t i c e s a r e u s e d . N O T E : S e in d iv id u a ls th e ir lo c a l fo r in f o r m a o u tlin e d in

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a . T r a n s m i s s i o n N a m e p l a t e . T h e n a m e p l a t e ( F i g u r e 1 – 7 ) i s l o c a t e d o n t h e r i g h t s id e o f t h e t r a n s m i s s i o n a n d i s i m p r i n t e d w i t h t h e f o l l o w i n g : • T r a n s m is s io n m o d e l • S e r ia l n u m b e r • D a te c o d e • T r a n s I D

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• E n g i n e e r i n g g r o u p s ( f o r S p e c i a l t y S e r i e s v o c a t io n m o d e ls ) U s e a l l o f t h e s e n u m b e r s w h e n o r d e r in g r e p l a c e m e n t p a r t s o r r e q u e s t i n g s e r v i c e i n f o r m a t i o n . b . P a r t s C a t a l o g . R e p l a c e m e n t p a r t s a r e l i s t e d in P a r t s C a t a lo g P C 2 1 5 0 E N a n d t h e P a r t s C a t a lo g o n t h e A llis o n E x t r a n e t . D o n o t o r d e r b y t h e it e m n u m b e r s u s e d o n d i s a s s e m b l e d v ie w s i n t h i s m a n u a l . U s e t h e p a r t s c a t a l o g t o d e t e r m in e t h e c o r r e c t p a r t n u m b e r . O r d e r a l l r e p l a c e m e n t p a r t s f r o m y o u r d i s t r i b u t o r o r a u t h o r i z e d d e a l e r . C h e c k t h e Y e l l o w P a g e s f o r y o u r n e a r e s t a u t h o r i z e d s e r v i c e o u t le t . L i s t in g s a r e u n d e r T r a n s m i s s io n — T r u c k , T r a c t o r , E t c . S e r v i c e o u t l e t s c a n a l s o b e l o c a t e d o n t h e A l l i s o n T r a n s m i s s io n w e b s it e a t w w w . a l l i s o n t r a n s m i s s i o n . c o m .

1 – 4 .

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u r , fi v e , o r s ix e c h a n ic a lly , e m ily t r a n s m is n s m is s io n . C e a s a fo u r o r e c ia lt y S e r ie s v e n fo rw a rd s

fo r w a r d v e ry 3 0 s io n m o a lib r a t io fi v e s p e (S P ) h a p e e d s .

s p e e d c o n fi g u r a t i o n s 0 0 P r o d u c t d e l i s a s ix s p e e d n s a r e a v a i l a b l e t o e d m o d e l) . T h e 3 7 0 0 s a t r a n s f e r c a s e a n d

• L o c k u p c lu t c h w it h t o r s io n a l d a m p e r • I n t e g r a l r e t a r d e r ( o p t i o n a l ) • E x t e r n a l l y a c c e s s i b l e o i l fi l t e r s , s e r v i c e a b l e w i t h o u t c o m p l e t e l o s s o f t r a n s m i s s i o n fl u i d • A d a p t i v e , e l e c t r o n i c , c l o s e d - l o o p c o n t r o l s w i t h s e l f - d i a g n o s t i c c a p a b i l i t i e s 1 - 6

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g . C o n t r o l S y s te m a n d T r a n s m is s io n M o d u l e ( T C M ) . T h e c o n t r o l s y s t e m i s c r e c o g n i z in g h y d r a u lic a n d e le c t r o n ic c o n a r e n o t w ith in th e o p e r a t in g lim it s o f t h e p c a lib r a tio n . S o m e o u t - o f - lim it c o n d it io n s c o r r e c t e d b y th e c o n t r o l s y s t e m . A ll o u t c o n d i tio n d i a g n o s t ic tr o u b le c o d e s a r e s l a t e r r e t r i e v a l b y a t e c h n i c i a n .

M O D U L E S

I n p u t M o d u l e . T h e i n p u t m o d u l e i n c l u d e s : • E n g i n e a d a p t a t i o n • T o r q u e c o n v e r t e r • P T O

b .

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p r o v is io n

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in c l u d e s :

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1 . T h e t o r q u e c o n v e r t e r i n c l u d e s a l o c k u p c l u t c h a n d t o r s io n a l d a m p e r f o r d i r e c t a n d s m o o t h t r a n s f e r o f e n g i n e p o w e r .

• S e n s o r s

2 . T h e a v a i la b le t o r q u e c o n v e r t e r m o d e l s a r e :

• W i r i n g h a r n e s s ( c u s t o m e r - f u r n i s h e d )

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m p u te r t h v a r io u s a il a b l e i n h th e c o n m .

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c . P o w e r T a k e o f f ( P T O ) P r o v i s i o n . P r o v i s i o n f o r a d i r e c t , e n g i n e - d r i v e n P T O i s a v a i l a b l e a t t w o p o s i t i o n s .

• C lu t c h a p p ly a n d r e l e a s e p r e s s u r e s T y p ic a l d a t a s e n t to th e T C M p r o c e s s i n g i n c l u d e s :

d . M a i n H o u s i n g a n d G e a r M o d u l e . T h e m a i n h o u s in g a n d g e a r m o d u l e in c lu d e s :

e d r s

• S h i f t s e l e c t o r p o s i t i o n

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• T w o r o t a t in g c lu t c h e s

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.

R a n g e C l u t c h e s . R R a n g e c l u t c h e s a r e m u l t i p l e i s c , w e t - t y p e c l u t c h e s . E x h a u s t b a c k fi l l p r e s s u r e e d u c e s fi ll t im e f o r q u i c k r e s p o n s e a n d s m o o t h h i f t s .

f. G e a rin g T a b le 1 – 1 .

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f o r c o m p i la t i o n a n d

• R e t a r d e r t e m p e r a t u r e • E n g i n e w a t e r t e m p e r a t u r e • P r e s s u r e S w it c h 1 ( P S 1 ) p r e s s u r e s w it c h s t a t u s • O il l e v e l • A n y s p e c i a l f u n c t i o n s o p e r a t i n g

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h . o il E a re m tra

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r s . T w o p a rt o f in a s e re p la c e fl u i d .


d is p o s a b le e x t e r n a l- a c th e c o n tro l v a lv e m o d u p a r a t e c a v ity w h ic h p e r m e n t w it h o u t c o m p le t e

c e s s l e . m i t s lo s s o f

i . T r a n s m i s s i o n F l u i d C o o l e r s . T h e m a in h o u s i n g a c c e p t s r e m o t e o r i n t e g r a l t r a n s m i s s i o n fl u i d c o o l e r s . j . O u tp u t C o n fi g u in c lu d e s e it h e r a n in fl a n g e , o r a re a r c o m o u n t i n g a p a r k in g y o k e is n o t a v a ila b le tr a n s m is s io n s . T h e a n d a d a p te r a s a n o

1 – 6 .

r a t i o n . T h e te g ra l re ta rd e v e r t h a t i n c lu b ra k e a n d a fl w it h p a r k in g 3 7 0 0 S P h a s u t p u t m o d u le

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M O D E L D E S IG N A T I O N

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T h e f o l lo w in g e x p l a i n s t h e t r a n s m is s io n m o d e l d e s i g n a t i o n c o d e s t a m p e d o n t h e t r a n s m i s s io n n a m e p l a t e f o r v o c a t io n a l m o d e l s . H ig h w a y S e r ie s

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B u s S e r ie s

B 2 9 5 , B 3 0 0 , B 4 0 0

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T 2 5 0 , T 2 5 5 , T 2 6 0 , T 2 6 5 , T 2 7 0 , T 2 8 0

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T 3 1 0 , T 3 2 5 , T 3 5 0 , T 3 7 5

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W id e s t R a t io C o v e r a g e ( W R C )

5 —

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1 - 8

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ily a l F (S P ro

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G E N E R A L V o c a t i o n a l M o d e l

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c .

f e r t o T S 3 9 8 9 E N , A l l i s o n 4 t h C o n t r o l s T r o u b l e s h o o t i n g i n - d e p t h t r o u b l e s h o o t i n g .

N O h a U s to

a . B e f o r e S t a r t i n g . B e f o r e a t t e m p t i n g t o r e p a i r t h e t r a n s m i s s i o n , i d e n t i f y t h e f a u l t y c o n d i t i o n a n d i t s p r o b a b l e c a u s e . b . C H E C K T o f t h e C H E C K in d ic a t e s t h e T h a s s ig n a l e d a s t a r t - u p , t h e C

R A N T R A ra n s D ia H E C

S N m g n K

L i g h t . C C o n t i n u e d i l l u m i n S l i g h t d u r i n g v e h i c l e o p is s io n C o n t r o l M o d u l e ( T o s tic T r o u b le C o d e ( D T C T R A N S l i g h t b r i e fl y i l l u m

E n t e r i n g D i a g n o s t i c M o d e . T E s n o e th d is p

: T h e s t r d is p la y e A llis o n la y D T C

i p p u s h b u t t o n s h i f t s e l e c t o r o r d i a g n o s t i c c a p a b i l i t i e s . D O C ® F o r P C – S e r v i c e T o o l s .

N O T E : A n o i l l e v e l s e n s o r i s s t a n d a r d w i t h 4 t h g e n e r a t i o n c o n t r o l s e x c e p t i n t h e 3 7 0 0 S P .

a t i o n e r a t i o n C M ) ) . A t i n a t e s .

N O T E : P r o g n o s t i c s i n f o r m a t i o n w a s o p t io n a l b e g i n n i n g w it h M Y 0 9 t r a n s m is s io n s . S e e S I L 1 1 - W T - 0 8 o r a n O p e r a t o r s M a n u a l t o v e r i f y v e h i c l e r e q u i r e m e n t s s h o u l d P r o g n o s t i c s i n f o r m a t i o n n o t d i s p l a y i n t h e s e l e c t o r . 1 . A c c e s s in g O i l L e v e l , P r o g n o s t i c s , a n d D ia g n o s t ic T r o u b l e C o d e s U s in g a L e v e r S h i f t S e l e c t o r

C o p y r ig h t ©

2 0 0 9


1 - 9

S E R V IC E


T h e D I S P L A Y M O D E /D I A G N O S T IC b u t t o n p r o v i d e s a c c e s s t o :

( D M D )

• S a a (

• F l u i d l e v e l i n f o r m a t i o n • P r o g n o s t i c s i n f o r m a t i o n

n e D o th n o

o u s ly p w n ) A r e T ra n s s t ic s is

r e s s t h e ↑ ( U p ) A r r o w r o w b u t t o n s a g a i n t o m i s s io n H e a l t h M o n i t o r a v a i l a b l e ) .

• S i m u l t a n e o u s l y p r e s s t h e ↑ ( U p ) A r r o w a n d ↓ ( D o w n ) A r r o w b u t t o n s a g a i n t o a c c e s s th e D T C s .

• D ia g n o s t i c t r o u b l e c o d e in f o r m a t io n . T o a c c e s s o i l le v e l , p r o g n o s t i c s , a n d D T C s : • M o v e t h e s h i f t l e v e r t o N N ( N e u t r a l ) a n d a p p l y t h e p a r k in g b r a k e .

• P r e s s t h e M O D E b u t t o n t o d i s p l a y t h e n e x t D T C . R e p e a t f o r c o d e p o s it io n s d 3 t h r o u g h d 5 .

• P r e s s t h e D I S P L A Y M O D E / D I A G N O S T I C b u t t o n o n c e t o a c c e s s o i l le v e l in f o r m a t io n ( e x c e p t 3 7 0 0 S P ) .

• P r e s s N ( N e u t r a l ) t t o e x i t t h e d i a g n o s t i c m o d e .

• P r e s s t h e D M D a g a in t o a c c e s s t h e O il L i f e M o n i t o r ( i f P r o g n o s t i c s i s a v a i l a b l e ) . • P r e s s t h e D M D a g a in t o a c c e s s t h e F i lt e r L i f e M o n i t o r ( i f P r o g n o s t i c s i s a v a i l a b l e ) . • P r e s s t h e D M D a g a in t o a c c e s s t h e T r a n s m i s s i o n H e a l t h M o n i t o r ( i f P r o g n o s t i c s i s a v a i l a b l e ) . • P re s s th e D M D i n f o r m a t i o n .

a g a in t o a c c e s s t h e D T C

d . D ia g n o s t ic T r o u b le C o d e s c a n b e d is p la y e d o n th e d is p la y s e l e c t o r o r A l l i s o n D O C ® F o r P C D T C is e ith e r a c t iv e o r h is to r ic . a n y D T C t h a t is c u r r e n t in t h e T C p r o c e s s . H is to r ic D T C s a r e D T C T C M m e m o ry a n d d o n o t n e c e s T C M d e c is io n m a k in g p r o c e s s . in d ic a te d o n th e s h ift s e le c t o r b y i n d i c a t o r b e i n g i l l u m i n a t e d .

( D T C s ) . D T C s p o r t io n o f t h e s h i f t – S e r v ic e T o o l. A A n a c t i v e D T C i s M d e c is io n m a k in g s r e t a i n e d i n t h e s a r ily a f f e c t t h e A c tiv e D T C s a r e t h e M O D E O N

• P r e s s t h e M O D E b u t t o n t o v i e w s u b s e q u e n t c o d e p o s i t i o n s d 2 t h r o u g h d 5 .

e . D i s p l a y i n g D i a g n o s t i c T r o u b l e C o d e s ( D T C s ) . T T h e p r o c e s s f o r d i s p l a y i n g D T C s d i f f e r s b e t w e e n t h e t w o b a s i c s t y le s o f s h i f t s e le c t o r s :

• T o e x it t h e D T C m o d e , m o v e t h e s h if t l e v e r t o a n o t h e r p o s i t i o n .

• P u s h b u t t o n s e l e c t o r s : s i m u l t a n e o u s l y p r e s s t h e U P S H I F T a n d D O W N S H I F T a r r o w s o n t h e s e l e c t o r .

2 . A c c e s s in g O i l L e v e l , P r o g n o s t i c s , a n d D ia g n o s t ic T r o u b le C o d e s U s in g a P u s h b u t t o n S h i f t S e l e c t o r T o a c c e s s o i l le v e l , p r o g n o s t ic s , a n d D T C s , d o t h e f o l lo w in g : • S e l e c t N ( N e u t r a l ) a n d a p p l y t h e p a r k i n g b r a k e s . • S a a 3

1 - 1 0

im u lta n d ↓ ( c c e s s if P r o g

im u lta n n d ↓ ( D c c e s s o 7 0 0 S P )

e o u s l y p r e s s t h e ↑ ↑ ( U p ) A r r o w o w n ) A r r o w b u t t o n s o n c e t o i l l e v e l i n f o r m a t i o n ( e x c e p t .

• S im u lta a n d ↓ ( to a c c e P ro g n o

n e o u s ly D o w n ) A s s th e O s t ic s is a

p r rr il v a

• S im u a n d to a c P ro g

n e o u s ly D o w n ) A s s th e F s t ic s is a

p r e s s t h e ↑ ( U p ) A r r o w r r o w b u t t o n s a g a i n i l t e r L i f e M o n i t o r ( i f v a i l a b l e ) .

lta ↓ ( c e n o

e s s t h e ↑ ( U p ) A r r o w o w b u t t o n s a g a i n L i f e M o n i t o r ( i f i l a b l e ) .

C o p y r ig h t ©

• L e v e r s e le c to r s : p r e s s th e D M D

b u t t o n .

f . D i a g n o s t i c T r o u b l e C o d e ( D T C ) D i s p l a y s . O n c e t h e d is p la y m o d e h a s b e e n in i t ia t e d : • I f t h e t r a n s m is s io n is e q u i p p e d w it h a n O L S , t h e fl u i d l e v e l i s d i s p l a y e d fi r s t . • I f p r o g n o s t i c s f u n c t i o n s a r e e n a b l e d i n t h e T C M C o n t r o l s c a l i b r a t i o n , t h e p r o g n o s t i c s r e a d o u t s a r e d i s p l a y e d n e x t . • D o o D ( b d (

T C s a r e t h e n d is p la y e d . E a c h D T C c o n f fo u r s e q u e n t ia l e le m e n t s , e a c h b e in g e n e o r t w o c h a r a c te r s . T h e d is p la y fo r e a T C r e p e a t s c o n t in u o u s ly u n t il th e n e x t D i f p r e s e n t ) i s a c c e s s e d b y p r e s s i n g t h e M u t to n . T h e f o llo w in g e x a m p l e illu s t r a te s i s p la y c y c le f o r t h e n e w e s t D T C i n m e m D T C P 2 5 3 4 is u s e d fo r illu s t r a t io n p u r p o s


s is ts i t h e r c h T C O D E t h e o r y e s ) :

G E N E R A L N O T E : d 1 = n e w e s t D T C , d 5 = o l d e s t D T C

IN F O R M A T IO N

in m e m o r y

d 1

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2 5

M a in D T C

3 4

S u b c o d e

d 1 ; P ; 2 5 ; 3 4

D T C r e p e a t s u n t il n e x t D T C ( d 2 ) is a c c e s s e d b y p r e s s i n g t h e M O D E b u t t o n

If th e c o n d t h e L E D in s im u lt a n e o c o n d it i o n w e x is ts , t h e m a in ta in e d c o n d i t i o n . T h e c o d e it e m d is p is d is p la y c y c le s c o is a c c e s s f o llo w in g d is p la y e d

t y p e

it io n w h ic h g e n e r a t e d t h e D T C is d ic a t o r o n t h e s e le c t o r is illu m in a u s ly w it h th e d is p la y o f th e D T C . h ic h g e n e r a te d t h e D T C n o lo n g L E D is n o t illu m in a t e d a n d th e D o n ly a s a h is to r ic a l r e c o r d o f th e

S E L E C T

o n

3 . W a i t u n t il t i m e - o u t ( a p p r o x i m a t e l y 2 m in u t e s ) . T h e s y s t e m s a u t o m a t ic a l l y r e t u r n t o t h e n o r m a l o p e r a t in g m o d e . 4 . T u r n o f f t h e v e h i c l e e n g i n e w i t h t h e i g n i t i o n s w it c h , w h ic h t u r n s p o w e r o f f t o t h e T C M .

1 – 8 .

S h i f t S e l e c t o r s M O N IT O R

d

1

1

3

1

2

T o v i e w t h e s e c o n d , t h i r d , f o u r t h , a n d fi f t h p o s i t i o n s ( d 2 , d 3 , d 4 , a n d d 5 ) , m o m e n t a r i l y p r e s s t h e M O D E b u t t o n a s e x p l a i n e d a b o v e . M o m e n t a r i l y p r e s s t h e M O D E b u t t o n a f t e r t h e fi f t h p o s i t i o n i s d i s p l a y e d t o r e s t a r t t h e s e q u e n c e o f c o d e l i s t p o s i t i o n s . A n a c t i v e D T C i s i n d i c a t e d b y t h e i l l u m i n a t i o n o f t h e L E D in d i c a t o r w h e n a c o d e p o s i t io n is d i s p la y e d w h i le in t h e d i a g n o s t ic d i s p la y m o d e . I n n o r m a l o p e r a t i n g m o d e , t h e L E D i n d i c a t o r i l l u m i n a t e s t o s h o w a s e c o n d a r y m o d e o p e r a tio n . A n y c o d e p o s it io n w h ic h d o e s n o t h a v e a D T C lo g g e d d is p la y s “ – ” f o r t h e D T C . N o D T C s a r e lo g g e d a f t e r a n e m p t y c o d e p o s i t i o n . g . E x it i n g D i a g n o s t i c M o d e . U s e a n y o f th e f o l l o w i n g m e t h o d s t o e x i t t h e d i a g n o s t i c d i s p l a y m o d e :

C o p y r ig h t ©

2 . W i t h l e v e r s h i f t s e l e c t o r s , m o m e n t a r i l y p r e s s t h e M O D E b u t t o n o r m o v e t h e s h i f t s e l e c t o r t o a n y s h i f t p o s i t i o n o t h e r t h a n t h e o n e s e l e c t e d w h e n t h e d i a g n o s t ic d i s p l a y m o d e w a s a c t i v a t e d . I f t h e s h i f t i s i n h i b i t e d d u e t o a s e r v ic e c o n d i t io n , t h e T C M c o n t in u e s t o c o m m a n d t h e c u r r e n t t r a n s m i s s io n r a n g e a t t a i n e d a n d t h e l e v e r s h o u l d b e r e t u r n e d t o i t s p r e v i o u s p o s i t i o n .

a c t iv e , t e d I f t h e e r T C is p r i o r

li s t o r q u e u e p o s i t io n ( d 1 ) is t h e fi r s t la y e d , f o l lo w e d b y t h e D T C . E a c h it e m e d f o r a b o u t o n e s e c o n d . T h e d i s p la y n t i n u o u s l y u n t i l t h e n e x t c o d e l i s t p o s i t i o n e d b y p r e s s i n g t h e M O D E b u t t o n . T h e e x a m p le s h o w s h o w D T C C 1 3 1 2 is o n t h e p u s h b u t t o n a n d le v e r s e l e c t o r s . L E D s

1 . W it h p u s h b u t t o n s h i f t s e l e c t o r s , s i m u l t a n e o u s l y p r e s s t h e U P S H I F T a n d D O W N S H I F T a r r o w s o r p r e s s a n y r a n g e b u t t o n , D ( D r i v e ) , N ( N e u t r a l ) , o r R R ( R e v e r s e ) . I f t h e s h i f t is n o t in h ib i t e d b y a n a c t i v e D T C , t h e T C M c o m m a n d s t h e t r a n s m i s s i o n t o s h if t t o t h e s e l e c t e d r a n g e .

2 0 0 9

P R E S E R V A T IO N

a . P r e s e rv a tio n M is s to r e d o r in a c tiv e o r m o re y e a rs ), s p e re q u ir e d to p r e v e n t a n d o r g a n ic g r o w th P r e s e r v a t io n m e t h o w ith o r w it h o u t t r a n s th e s a m e w h e th e r a v e h i c l e .

A N D

S T O R A G E

e t h o d s . W h e n t h e t r a n s m i s s i o n f o r a n e x t e n d e d p e r i o d ( o n e c i fi c p r e s e r v a t i o n m e t h o d s a r e d a m a g e f r o m r u s t , c o r r o s i o n , in t h e t r a n s m is s io n fl u i d . d s d e s c r ib e d a r e f o r s t o r a g e m i s s io n fl u i d . T h e m e t h o d s a r e t r a n s m is s io n is in o r o u t o f a

b . S t o r a g e ( N e w T r a n s m i s s i o n s , B e f o I n s t a l l a t i o n ) . N e w t r a n s m i s s i o n s a r e fi l l e t r a n s m is s io n fl u id a n d d r a i n e d b e f o r e s h ip r e s id u a l fl u i d in t h e t r a n s m is s io n p r o v id e s p r o t e c t io n to s a f e l y s t o r e t h e tr a n s m is s io n fu ll y e a r w ith o u t fu r th e r t r e a t m e n t if s t o r e d in c o n d i tio n s o f n o r m a l c l im a t e , a n d w ith a p l u g s i n s t a l l e d . c .

r e d w i t h m e n t . T h e a d e q u a t e f o r o n e i n d o o r s , l l s h i p p i n g

O n e Y e a r S t o r a g e ( W i t h o u t F l u i d ) . 1 . D r a i n t h e fl u id . 2 . R e m o v e t h e b r e a th e r a n d s p r a y 3 0 m l ( o n e o u n c e ) o f V C I # 1 0 ( o r e q u i v a l e n t ) i n t o t h e t r a n s m is s io n t h r o u g h t h e b r e a t h e r h o l e .


1 - 1 1

S E R V IC E


R e - i n s t a l l b r e a t h e r . A l s o , s p r a y 3 0 m l ( o n e o u n c e ) t h r o u g h t h e fi ll t u b e h o le .

8 . C o a t a l l e x p o s e d , u n p a i n t e d s u r f a c e s w i t h p r e s e r v a t i v e g r e a s e s u c h a s p e t r o l a t u m ( M I L - C - 1 1 7 9 6 ) , C la s s 2 .

3 . S e a l a l l o p e n in g s a n d t h e b r e a t h e r w it h m o i s t u r e - p r o o f t a p e .

9 . If a d d i tio n a l s t o r S te p s 2 th r o u g h it is n o t n e c e s s a e a c h y e a r. J u s t ( o r e q u i v a l e n t ) .

4 . C o a t a l l e x p o s e d , u n p a i n t e d s u r f a c e s w i t h p r e s e r v a t i v e g r e a s e s u c h a s p e t r o l a t u m ( M I L - C - 1 1 7 9 6 , C la s s 2 ) . 5 . I f a d d i t i o n a l s t o r a g e t i m e i s r e q u i r e d , r e p e a t S t e p s 3 a n d 4 a t y e a r ly in t e r v a ls . d .

1 – 9 .

O n e Y e a r S t o r a g e ( W i t h F l u i d ) . 1 . D r a in t h e fl u id a n d e l e m e n t s 2 . F ill m ix to 3 ( 1 / 4 e q u o f fl

th tu 0 te iv u

e t r a n s m is s io re o f o n e p a r p a rts tra n s m a s p o o n p e r g a le n t ) p e r 3 m id in th e s y s t e

N O T E : W h e n c B i o b o r ® J F r e q u th e s y s te m , n o t fi ll t h e t r a n s m is s fi lte r s , a n d th e c

n to o p e r a t in g t V C I # 1 0 (o r is s io n fl u id . A a llo n ) o f B io b l ( 1 / 4 t e a s p o o m .

a lc u la t i n g ire d , u s e ju s t t h e q io n . In c lu o o l e r .

th e th e u a n d e

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o u n t o l v o lu m re q u ire r n a l lin

f e o f d t o e s ,

5 . C o n t in u e o p e r a t in g t h e t r a n s m is s io n i n n e u t r a l a t 1 5 0 0 r p m u n t il n o r m a l o p e r a t in g t e m p e r a t u r e is r e a c h e d . o p 2 5 a n 0 7

e r a t in g t e m p e r a t u r e i s le s s t h a n ° F ) , s h i f t t h e t r a n s m i s s i o n t o g e a n d s t a l l t h e c o n v e r t e r . D o n o t ° C ( 2 2 5 ° F ) .

N O T E : I f t h e u n i t d o e s n o t h a v e a c o n v e r t e r - o u t t e m p e r a t u r e g a u g e , d o n o t s t a l l t h e c o n v e r t e r . 7 . A s s o o n a s t h e t r a n s m is s io n is c o o l e n o u g h t o t o u c h , s e a l a l l o p e n i n g s a n d t h e b r e a t h e r w i t h m o i s t u r e - p r o o f t a p e .

1 - 1 2

e is a r ly a in I # 1

re q u ire d , in t e r v a ls , th e tra n s m 0 a n d B io

r e p e a t e x c e p t , i s s i o n b o r ® J F

R E S T O R IN G T R A N S M IS S IO N S E R V I C E

T O

C A U T I O N : W h e n e v e r a t r a n s m i s s i o n i s o v e r h a u l e d , e x c h a n g e d , o r h a s u n d e r g o n e r e p a i r s , t h e T r a n s m i s s i o n C o n t r o l V a l v e M o d u le ( T C M ) m u s t b e “ R E S E T T O U N A D A P T E D S H I F T S . ” T h is w ill c a u s e t h e T C M t o e r a s e p r e v i o u s a d a p t iv e in f o r m a t io n a n d b e g in t o a d a p t i n F a s t A d a p t iv e M o d e f r o m t h e b a s e c a l i b r a t i o n . U s e t h e A l l i s o n D O C ® F o r P C – S e r v i c e T o o l ( r e f e r t o t h e A l l i s o n D O C ® U s e r ’ s G u i d e G N 3 4 3 3 E N f o r in s t r u c t io n s ) t o “ R E S E T T O U N A D A P T E D S H I F T S . ”

l w i t h a a le n t ) m l F ( o r g a l lo n )

4 . M a k e s u r e t h e t r a n s m is s io n s h i f t s t h r o u g h a l l r a n g e s a n d t h e lo c k u p c lu t c h is a l s o a c t iv a t e d .

a l (2 r 1

e t im a t y e to d r d V C

r e p l a c e t h e o i l fi l t e r

3 . O p e r a t e t h e t r a n s m i s s i o n f o r a p p r o x i m a t e l y fi v e m i n u t e s a t 1 5 0 0 r p m w i t h t h e t r a n s m i s s io n i n n e u t r a l .

6 . If n o r m 1 0 7 ° C fo r w a r d e x c e e d

a g 8 ry a d

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a . T r a n s m i s s i o n E x t e r i o r . W a s h a l l e x t e r n a l g r e a s e f r o m t h e t r a n s m i s s i o n w i t h m i n e r a l s p i r i t s . b . S e a l e d B r e a t h e r a n d O p e n i n g s . R e m o v e a l l t a p e f r o m o p e n i n g s a n d t h e b r e a t h e r . c . n e th e a p

N e w T w , d r a in tra n s m p ro v e d

d . S to r e p r e p a re d fl u id a n d t r a n s m is s a p p ro v e d e . p re p to d tra n o r d th e

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i t h o u t F l u i d . I f t h e s t o r a g e w ith o u t fl u i d , la c e th e o il fi lte r e le m to th e p r o p e r le v e l w n s m is s io n fl u i d .

e d W ith F lu fo r s to r a g e a n d r e fi ll t h e s io n fl u id . C t r a n s m is s io n e r le v e l.


i d . I f t h e t r a w ith fl u id , it t r a n s m is s io h e c k fo r p r o p fl u id , a s re q

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n s m a in ts . a n

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n s m is s io n w a s i s n o t n e c e s s a r y n w i t h n e w e r fl u i d l e v e l . A d d u i r e d , t o o b t a i n

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e ta ile d t r a n s m is s io n e 3 0 0 0 a n d 4 0 0 0 P r p e r a t io n M a n u a l, P O p e r a t o r ’s M a n u a ls ( s t e s t r e v i s i o n .

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in fo r ilie s o r v o 8 – 1 ).

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c a tio n s a n d d e m a jo r c h a r a d e t a ile d in f o r m T e c h D a ta b o

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3 0 0 0 / 3 2 0 0

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3 .4 9 :1

4 .5 9 :1

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1 .8 6 :1

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H Y D R A U L IC

S Y S T E M :

F l u i d t y p e

A l l is o n a p p r o v e d T E S - 2 9 5 fl u id , M I L - L - 2 1 0 4 , M I L - L - 4 6 1 6 7 , M I L - P R F - 2 1 2 6 0 , D E X R O N ® - V I , T E S 3 8 9

F i lt e r s , m a in a n d c o o le r

D u a l i n t e g r a l , r e p l a c e a b l e c a r t r id g e t y p e

C o o le r

R e m o t e m o u n t e d , o p t io n a l i n t e g r a l

S IZ E S :

B a s e T r a n s m i s s i o n

W it h P T O P r o v i s i o n

W ith R e ta r d e r

W it h P T O P r o v i s i o n a n d R e t a r d e r

3 7 0 0 S P

L e n g t h ( t r a n s m i s s i o n m o u n tin g f a c e t o e n d o f o u t p u t s h a f t )

7 1 9 .4 m m ( 2 8 . 3 2 i n )

8 2 1 .9 m m ( 3 2 . 3 6 i n )

7 1 8 .6 m m ( 2 8 . 2 9 i n )

8 2 1 .6 m m ( 3 2 . 3 5 i n )

1 3 1 0 . 3 m m ( 5 1 . 5 8 i n )

D e p t h ( c e n t e r l i n e t o l o w e s t 3 2 7 . 7 m m p o i n t ) ( 1 2 . 9 0 i n )

3 2 7 .7 m m ( 1 2 . 9 0 i n )

3 2 7 .7 m m ( 1 2 . 9 0 i n )

3 2 7 .7 m m ( 1 2 . 9 0 i n )

5 5 5 .3 m m ( 2 1 . 8 7 i n )

D r y W e ig h t

2 6 1 k g ( 5 7 5 lb )

2 7 9 k g ( 6 1 5 lb )

2 9 7 k g ( 6 5 5 lb ) 5 3 0 k g ( 1 1 7 0 l b )

2 4 3 k g ( 5 3 5 lb )

D r y W e i g h t w i t h i n t e g r a l r e t a r d e r s u m p c o o l e r

3 3 6 . 5 k g ( 7 4 0 lb )

*

A l l d a t a a n d s p e c i fi c a t i o n s a r e s u b j e c t t o c h a n g e w i t h o u t n o t i c e . G e a r r a t i o s d o n o t i n c l u d e t o r q u e c o n v e r t e r m u l t i p l i c a t i o n .

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2 0 0 9


1 - 1 3

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1 – 1 2 .


E L E C T R O M A G N E T IC /R A D I O F R E Q U E N C Y IN T E R F E R E N C E

A l l e l e c t r i c a l a n d e l e c t r o n i c s y s t e m s g e n e r a t e e l e c t r o m a g n e t i c fi e l d s t h a t c a n i n t e r f e r e w i t h o t h e r e l e c t r o n i c s y s t e m s . A l l i s o n T r a n s m i s s i o n ’ s e l e c t r o n i c t r a n s m i s s i o n c o n t r o l s c o m p l y w i t h F e d e r a l C o m m u n i c a t i o n s C o m m i s s io n ( F C C ) r e g u l a t i o n s a n d o t h e r g u i d e l i n e s c o n c e r n i n g e m i t t e d r a d i o f r e q u e n c y i n t e r f e r e n c e f o r t r a n s p o r t a t i o n e l e c t r o n i c s . S o m e r a d i o - t e l e p h o n e o r t w o - w a y c o m m u n i c a t io n s r a d i o s ( l a n d - m o b i l e r a d i o ) , o r t h e m a n n e r i n w h i c h t h e y a r e i n s t a l l e d , c a n b e a f f e c t e d b y o t h e r v e h i c l e c o m p o n e n t s o r a d v e r s e l y a f f e c t v e h ic l e o p e r a t io n . M a n u f a c t u r e r s a n d i n s t a l l e r s o f E l e c t r o m a g n e t i c I n t e r f e r e n c e ( E M I ) / R a d i o F r e q u e n c y I n t e r f e r e n c e ( R F I ) e m i t t i n g e q u i p m e n t a r e r e s p o n s i b l e f o r a d h e r in g t o F C C r e g u l a t io n s a n d o t h e r g u id e l in e s c o n c e r n i n g e m i t t e d r a d i o f r e q u e n c y i n t e r f e r e n c e f o r t r a n s p o r t a t i o n e l e c t r o n i c s . R a d i o o r o t h e r t w o - w a y c o m m u n i c a t io n a n t e n n a , p o w e r , o r g r o u n d le a d s n e a r t h e t r a n s m is s io n w ir in g h a r n e s s , c o n t r o l d e v ic e s , o r p o w e r l e a d s m a y c r e a t e o r b e s u b je c t t o E M I . R e f e r t o t h e l a t e s t r e v i s i o n o f A l l i s o n 4 t h G e n e r a t io n C o n t r o l s T r o u b l e s h o o t in g M a n u a l, T S 3 9 8 9 E N , f o r d e t a i l e d in s t r u c t io n s r e g a r d i n g E M I p r o b le m s .

1 - 1 4

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S E C T IO N 2 – 1 . P th P th tr tr te

ro e e r is a n a n r m

M S w v T a fl u

a n c e e n a b l e s r e q u i r e m e n t s . u r e s d e s c r i b e d i n p r e v e n t p r e m a t u r e n t f a i l u r e . A l l i s o n t o p r o v i d e l o n g i g n e d a p p l i c a t i o n s .

o d e l Y e a r 0 9 t r a n s m is s io n s ( M Y 0 9 b e g i n s w it h / N 6 5 1 0 8 2 2 0 0 5 , 6 5 2 0 0 9 9 9 5 7 ) a r e e q u ip p e d it h a p r o g n o s t ic s s y s t e m — c o m p r is e d o f c o n t r o l a l v e m o d u l e h a r d w a r e , t h e s h i f t s e l e c t o r , t h e r a n s m i s s io n C o n t r o l M o d u l e ( T C M ) c o n fi g u r a t i o n n d t h e c a l ib r a t io n — d e s i g n e d t o m o n it o r fl u i d lif e , u i d fi l t e r l i f e , a n d c l u t c h l i f e . P r o g n o s t i c s m a y b e s e d o n l y if a T E S 2 9 5 fl u id is in t h e t r a n s m is s io n .

ro g n o O C ® llo w m e le c to

M A I N T E N A N C E

b . F i l t e r L i f e M o n i t o r . F i l t e r d e t e r i o r a t i o n i s s e n s e d b y a d i f f e r e n t ia l p r e s s u r e s w i t c h ( P S 2 ) l o c a t e d i n t h e c o n t r o l v a l v e m o d u l e . T h e p r e s s u r e d i f f e r e n c e b e t w e e n fi l t e r e d l o c k u p p r e s s u r e a n d u n fi lt e r e d m a i n p r e s s u r e i s c o m p a r e d t o a c a l ib r a t e d v a lu e . I f t h e T C M d e t e r m in e s t h e fi lt e r h a s d e t e r i o r a t e d , t h e p r o g n o s t i c s e r v i c e i n d i c a t o r i c o n d i s p l a y s o n t h e s h i f t s e l e c t o r . C a l e n d a r b a s e d fi l t e r c h a n g e r e q u i r e m e n t s s t i ll a p p l y a n d a r e n o t in c o r p o r a t e d in t o p r o g n o s t i c s . R e f e r t o t h e m o s t c u r r e n t v e r s io n o f S I L 1 0 - T R - 9 9 .

P r o g n o s t i c s

I f fl u id c h a n g e , fi lte p e r f o r m e d w ith in a T r o u b le C o d e ( D T C l i g h t , a n d / o r a S E R w r e n c h ic o n ) in th e l ig h t i n t h e d a s h . P D a s

P R E V E N T IV E

S C O P E

p e r c a r e a n d r e g u la r m a in t e n t r a n s m is s io n t o m e e t it s d u t y fo r m th e m a in te n a n c e p r o c e d s e c t io n o n a r e g u la r b a s is to s m is s io n o r s u p p o r t e q u ip m e s m is s io n s a r e m a n u f a c t u r e d , e ffi c ie n t s e r v ic e in th e ir d e s

2 – 2 .

2 —

r c h a n g e , o r c lu t c h s e t p e r io d o f t im e , ) s e t s w i t h a C H E V I C E T R A N S l i g h t s h ift s e le c t o r o r a s

s e r a D C K (s h a n

v ic ia g T R o w a d

e is n o s A N n a s d it io

N O T E : T h e fi l t e r l i f e m o n i t o r f e a t u r e i s n o t a v a i l a b l e w i t h s e v e n s p e e d t r a n s m i s s i o n m o d e ls .

n o t t i c S t h e n a l

s t ic s c a n b e r e s e t t h r o u g h t h e A l l is o n F o r P C — S e r v ic e T o o l o r , i f c a l ib r a t e d t o a n u a l r e s e t , t h r o u g h m a n i p u l a t i n g t h e s h i f t r .

a . O i l L i f e M o n i t o r . T r a n s m i s s i o n o p e r a t i n g p a r a m e t e r s a r e m o n i t o r e d t o d e t e r m i n e r e m a i n i n g fl u i d a n d fi l t e r l i f e , a s w e l l a s :

c . T r a n s m is s m o n ito r s th e r u a n d C 5 c lu t c h e C lu t c h r u n n in g v o lu m e , in d ic a t lo c k u p c lu t c h e s

i o n H e a l t h . T r a n s m is s io n h e a n n i n g c le a r a n c e o f C 1 , C 2 , C 3 s t o d e t e r m in e c lu t c h p la t e w e c le a r a n c e , b a s e d u p o n c lu t c h e s r e m a i n i n g c lu t c h lif e . T h e C a r e n o t m o n i t o r e d .

l t h , C 4 , a r . fi ll 6 a n d

d . S h i f t S e l e c t o r D i s p l a y . O n l y s ix s p e e d t r a n s m i s s i o n s u s i n g A l l i s o n p u s h b u t t o n o r l e v e r s h i f t s e l e c t o r s c a n d i s p l a y t h e p r o g n o s t i c s e r v i c e i n d i c a t o r i c o n . P r e s s i n g l e v e r s h i f t s e l e c t o r D i a g n o s t i c b u t t o n o r s i m u l t a n e o u s l y p r e s s i n g t h e p u s h b u t t o n s h i f t s e l e c t o r a r r o w b u t t o n s e n t e r s t h e d i a g n o s t i c m o d e a n d c y c le s t h e s h i f t s e le c t o r d i s p l a y . T a b l e 2 – 1 c o r r e l a t e s t h e n u m b e r o f b u t t o n p r e s s e s w it h t h e t y p e o f d i a g n o s t ic d i s p la y . T a b l e 2 – 1 . S h i f t S e l e c t o r D i s p l a y P r e s s o r D i a g n o s t i c

• O p e r a t in g t im e • R e t a r d e r o p e r a t i o n

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W h e n o p e r a t in g p a r a m e t e r s r e a c h o r e x c e e d a c a l i b r a t e d v a l u e t h e T C M i l l u m i n a t e s t h e p r o g n o s t i c s e r v i c e i n d i c a t o r i c o n o n t h e s h i f t s e l e c t o r . C a l e n d a r b a s e d fl u id c h a n g e r e q u i r e m e n t s s t ill a p p l y a n d a r e n o t in c o r p o r a t e d in t o p r o g n o s t ic s . R e f e r t o t h e m o s t c u r r e n t v e r s io n o f 1 0 - T R - 9 9 .

C o p y r ig h t ©

2 0 0 9


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2 - 1

S E R V IC E


• O il le v e l d is p l a y in d ic a t e s t h e “ H I o r “ L O ” a n d t h e n u m b e r o f q u a r t s h ig h o r lo w • O i l l i f e m o n i t o r d i s p l a y i n d i c a t e s t h e p e r c e n t a g e o f o i l l i f e r e m a i n i n g — “ 8 8 ” , “ 0 2 ” • F i l t e r l i f e m o n i t o r d i s p l a y i n d i c a t e s t h e p e r c e n t a g e o f fi l t e r l i f e r e m a i n i n g — “ 9 5 ” , “ 1 0 ” • T r a n s H e a l t h d i s p l a y in d ic a t e s t h e s t a t u s o f c l u t c h l i f e — ” O K ” , “ L O ” • D T C

d i s p l a y s t h e d i a g n o s t i c t r o u b l e c o d e l is t

N O T E : F o r a d d i t i o n a l p r o g n o s t i c s in f o r m a t io n s e e S I L 1 1 – W T - 0 8 .

2 – 3 . a .

P E R IO D IC IN S P E C T IO N A N D

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E x t e r i o r C l e a n i n g a n d I n s p e c t i o n . C A tra a n c o

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a s h t h e r s . W a t e r c t r ic a l f a u l t y .

r io r o f t h e r v a l s . S e v e r i t y o f i t i o n s d e t e r m i n e s .

2 . I n s p e c t t h e t r a n s m is s io n f o r : • L o o s e b o l t s — t r a n s m i s s io n a n d m o u n t i n g c o m p o n e n t s • F lu i d le a k s ( r e f e r t o S I L 1 2 - W T - 0 2 ) — r e p a i r i m m e d i a t e l y • L o o s e , d i r t y , o r i m p r o p e r l y a d j u s t e d t h r o t t l e s e n s o r • D a m a g e d o r lo o s e h o s e s • W o r n , f r a y e d , o r i m p r o p e r l y r o u t e d e l e c t r i c a l h a r n e s s e s • D e n t e d , w o r n , o r o u t - o f - p h a s e d r i v e l i n e U - jo i n t s a n d s l i p fi t t i n g s • C lo g g e d o r d i r t y b r e a t h e r • C h e c k t r a n s m i s s io n fl u i d f o r e v i d e n c e o f e n g i n e c o o l a n t

2 – 4 .

IM P O R T A N C E L E V E L

C o p y r ig h t ©

F L U ID

a . T r a n s m i s s i o n F l u i d . T r a n s m i s s i o n fl u i d c o o l s , l u b r i c a t e s , a n d t r a n s m i t s h y d r a u l i c p o w e r . A l w a y s m a i n t a i n t h e c o r r e c t fl u i d l e v e l . I f t h e l e v e l i s t o o l o w , t h e t o r q u e c o n v e r t e r a n d c lu t c h e s d o n o t r e c e i v e e n o u g h fl u i d a n d t h e t r a n s m i s s io n o v e r h e a t s . I f t h e le v e l i s t o o h i g h , t h e fl u i d a e r a t e s c a u s i n g t h e t r a n s m i s s i o n t o s h i f t e r r a t i c a l l y a n d o v e r h e a t . F l u i d m a y b e e x p e l l e d t h r o u g h t h e b r e a t h e r o r d i p s t i c k t u b e w h e n t h e fl u id le v e l is t o o h i g h . b . O i l L e v e l S e n s o r . T h e O i l L a llo w s th e o p e r a t o r to c h e c k th e e it h e r a fu ll- fu n c t io n p u s h b u t to n s e l e c t o r . W h e n a n A l l i s o n 4 t h G s tr ip - ty p e p u s h b u t t o n s e le c t o r is le v e l in f o r m a t io n c a n o n ly b e r e a D O C ® F o r P C – S e r v i c e T o o l .

2 – 5 . a . S e n fa m fl u id A l l i s f o llo

E le s o r ilie s le v o n w in

T R A N S M IS S IO N c tr o n ic C ( O L S ) is e x c e p t th e l c a n b e D O C ® F o g p ro c e d u

h e c k P ro s ta n d a r d e 3 7 0 0 S d is p la y e d r P C – S e r r e t o d is p

e v e l fl u id o r a e n e r u s e d d u s

F L U ID

S e n s o r ( O L S ) le v e l f r o m l e v e r s h i f t a t i o n C o n t r o l s , t h e O L S fl u i d i n g A l l i s o n

C H E C K

c e d u r e . A n O il L e v e l f o r a ll 3 0 0 0 p r o d u c t P . T h e t r a n s m i s s io n o n t h e s h i f t s e le c t o r o r v i c e T o o l d i s p l a y . U s e t h e l a y fl u i d l e v e l i n f o r m a t i o n .

1 . F o r a p u s h b u t t o n s e l e c t o r , s i m u l t a n e o u s l y p r e s s t h e ↑ ( U p ) a n d ↓ ( D o w n ) a r r o w b u t t o n s o n c e . 2 . O n t h e l e v e r s h i f t s e l e c t o r , p r e s s t h e D D I S P L A Y M O D E b u t t o n o n c e . 3 . F o r t h e A l l i s o n D O C ® F o r P C – S e r v i c e T o o l , r e f e r t o t h e A l l i s o n D O C ® F o r P C – S e r v i c e T o o l U s e r G u id e G N 3 4 3 3 E N . b . F l u i d L e v e l D i s p l a y C r i t e r i a . A s s o o n a s fl u i d l e v e l i n f o r m a t i o n i s r e q u e s t e d , t h e T r a n s m i s s i o n C o n t r o l M o d u le ( T C M ) c h e c k s t o s e e if t h e c o n d i t i o n s a r e r i g h t t o a l l o w d i s p l a y . C e r t a i n o p e r a t in g c o n d i t io n s m u s t b e m e t f o r a p e r io d o f t w o m i n u t e s b e f o r e fl u i d l e v e l i s d i s p l a y e d . T h e d i s p l a y fl a s h e s a n d a n 8 , 7 , . . . . 1 c o u n t d o w n o c c u r s . F l u i d l e v e l i n f o r m a t i o n d i s p l a y s a f t e r t h e c o u n t d o w n i f t h e f o l lo w in g c o n d it io n s h a v e b e e n m e t : • E n g i n e a t i d l e

2 - 2

O F P R O P E R


P R E V E N T IV E


• S u m p fl u id t e m p e r a t u r e a t 6 0 – 1 0 4 ° C ( 1 4 0 – 2 2 0 ° F )

D i s p l a y ( F o r m e r )

• T r a n s m i s s io n o u t p u t s h a f t s t o p p e d o L —

• T r a n s m i s s i o n i n N N ( N e u t r a l ) . • O L S

S h i f t s e l e c t o r d i s p l a y fl u i d l e v e l i n f o r m a t i o n i s d i s p la y e d t w o c h a r a c t e r s a t a t im e a s s h o w n in T a b le 2 – 2 . T a b l e 2 – 2 . F l u i d L e v e l S h i f t S e c t o r D i s p l a y D is p la y S e q u e n c e

I n t e r p r e t a t i o n o f D i s p l a y

o L , o K

F lu id le v e l is c o r r e c t

L o

o L

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T h e s h ift s tw o c h a r a c is r e t u r n e d b u t a n o p e in v a l id fo r s h o w n in T

0 1

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F L

S e n s o r fa ilu r e

N d ( s a T n

O T E : R e p o r t s e n s o r f a il u r e t o a i s t r i b u t o r o r d e a l e r i n y o u r a r e a . C h e c k t h e A l l i s o n T r a n s m i s s io n w e b i t e w e w w w . a l l i s o n t r a n s m i s s i o n . c o m o r t e l e p h o n e d i r e c t o r y f o r a n A l l i s o n r a n s m i s s i o n d i s t r i b u t o r o r d e a l e r e a r e s t y o u . )

F lu id le v e l is 1 q u a r t lo w

O n A l l i s o n d i a g n o s t i c t o o l s , i n v a l i d f o r d i s p l a y m e s s a g e s a r e s h o w n in t h e O il ( ± ) fi e ld o f t h e D a t a M o n i t o r a s s h o w n in T a b le 2 – 4 .

F lu id le v e l is 1 q u a r t h ig h

, ( N )

In v a lid N = n u m (a lp h a b e a n

e le c t o r s h o w s in v a t e r s a t a t im e . A n w h e n th e fl u id le v r a t i o n a l c o n d i t i oo n d is p la y c o d e s a n d a b le 2 – 3 .

lid in v e l h a th

F o r e r ic t ic a l d n e

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fo r d is p la y a l id f o r d is d a t a is r e q s n o t b e e n e ir m e a n in

p l a y i s p la y M Y 0 8 )

T a b l e 2 – 4 . I n v a l i d f o r D i s p l a y M e s s a g e s

c o d e s p l a y c o d e u e s t e d , m e t. T h e g a r e

D D R

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o L —

0 X

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5 0

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D i s p l a y ( M Y 0 8 , C a l / S f w o r n e w e r )

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• P u s h b u t to n s h ift s e le c t o r — ( N e u t r a l ) b u t t o n o n c e .

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• L e v e r s h i f t s e l e c t o r — p r e s s t h e M O D E b u t t o n o n c e o r m o v e t h e le v e r.

o L —

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N ( N e u t r a l ) m u s t b e s e l e c t e d

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T a b l e 2 – 3 . I n v a l i d f o r D i s p l a y C o d e s

M e s s a g e

S E T T L IN G

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D i s p l a y ( F o r m e r )


* A n u m b e r b e t w e e n 8 a n d 1 t h a t fl a s h e s d u r in g t h e c o u n t d o w n p e r io d .

f u n c t i o n i n g p r o p e r l y

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D i s p l a y ( M Y 0 8 , C a l / S f w o r n e w e r )

C o p y r ig h t ©

2 0 0 9

E x it F lu i d L e v e l M o d e a s f o l lo w s : p r e s s t h e N

• F o r A l l i s o n D O C ® F o r P C – S e r v i c e T o o l , f o l l o w d i r e c t i o n s i n t h e A l l i s o n D O C ® U s e r G u i d e G N 3 4 3 3 E N .


2 - 3

S E R V IC E

2 – 6 .


M A N U A L F L U ID L E V E L C H E C K P R O C E D U R E W o a c

A R N I N G : T o r p ro p e rty d a n d u n e x p e c te h e c k th e fl u id

h e lp m a g e d v e h u n t il

p r e v e n t p e r s o n a l i n j u r y c a u s e d b y s u d d e n ic le m o v e m e n t , d o n o t y o u :

• P u t th e t r a n s m is s io n ( N e u t r a l ) … a n d

i n N N

• A p p ly t h e p a r k in g b r a k e a n d e m e r g e n c y b r a k e s a n d m a k e s u r e t h e y a r e p r o p e r ly e n g a g e d … a n d • C h o c k t h e w h e e ls a n d t a k e a n y o th e r s t e p s n e c e s s a r y t o k e e p t h e v e h i c l e f r o m m o v in g . a . P r o f th e D o n o tra n s m s y s te m tra n s m

e p fl u t a is

a r id llo s io m a is s io

a t i o n . C C fi ll t u b e w d ir t o r n . D ir t o y c lo g p n p a rt w

le a n a ll d ir t f r o m a r o b e fo r e r e m o v in g th e fo r e ig n m a tte r to e n r fo r e ig n m a tt e r in th a s s a g e s a n d c a u s e e a r o r s tic k in g v a lv e

u n d t t h e e n d d i p s t i c k . t e r t h e e h y d r a u l i c u n d u e s .

b . C o n s i s t e n c y o f R e a d i n g s . A lw a y s c h e c k t h e fl u i d le v e l r e a d i n g a t le a s t t w ic e u s i n g t h e f o llo w in g C o ld C h e c k a n d H o t C h e c k p r o c e d u r e s . C o n s i s t e n c y ( r e p e a t a b l e r e a d i n g s ) i s i m p o r t a n t t o m a i n t a i n i n g p r o p e r fl u i d l e v e l . I f i n c o n s i s t e n t r e a d i n g s p e r s i s t , c h e c k t h e t r a n s m i s s i o n b r e a t h e r t o b e s u r e it is n o t c lo g g e d . I f r e a d i n g s a r e s t ill i n c o n s i s t e n t , c o n t a c t y o u r n e a r e s t A l l i s o n d i s t r i b u t o r o r d e a l e r .

2 – 7 .

C O L D

C H E C K

( F ig u r e 2 – 1 )

b .

C o ld C h e c k P r o c e d u r e . 1 . P a r k t h e v e h i c le o n a le v e l s u r f a c e , c h o c k t h e w h e e ls , a n d a p p l y t h e p a r k in g b r a k e . 2 . R u n t h e e n g in e a a b o u t o n e m in u te t o R ( R e v e r s e ) t o o f a i r. T h e n s h ift e n g in e to r e m a in

2 - 4

r t h e n t e m t h e

4 . I n s e r t t h e d i p s t i c k i n t o t h e t u b e u n t i l i t s t o p s a n d r e m o v e . C h e c k t h e fl u id le v e l. R e p e a t t h e c h e c k p r o c e d u r e t o v e r if y t h e r e a d i n g . 5 . I f t h e fl u id le v b a n d , th e tra n th e fl u id is h o C H E C K ” p ro c w it h in t h e “ C O a s n e c e s s a ry m id d le o f th e

e l is w it h in t h e “ C O L D C H E C K ” s m is s io n c a n b e o p e r a t e d u n t il t e n o u g h t o p e r f o r m a “ H O T e d u r e . I f t h e fl u id le v e l is n o t L D C H E C K ” b a n d , a d d o r d r a in t o b r in g t h e fl u id le v e l t o t h e “ C O L D C H E C K ” b a n d .

6 . P e r f o r m a h o t c h e c k a t t h e fi r s t o p p o r t u n i t y a f t e r n o r m a l o p e r a t i n g t e m p e r a t u r e i s r e a c h e d — 7 1 – 9 3 ° C ( 1 6 0 – 2 0 0 ° F ) .

2 – 8 .

H O T C H E C K C A U T I O N : W h e n p r o c e d u r e , th e fl u te m p e r a tu r e to b e a n d h e lp p re v e n t T h e fl u id le v e l r is in c r e a s e s . D u r in g t r a n s m i s s io n c a n le a d in g to tr a n s m

l r is e s a s O N O T fi ll a n d if t h e n o r m a l o p e r a t i n g r a t io n a n o v e r f u l l o v e r h e a t e d , m a g e .

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0 rp m ) fo r iv e ) a n d r a u lic s y s a n d a llo w 0 0 r p m ) .

3 . W i t h t h e e n g in e r u n n in g , r e m o v e t h e d i p s t ic k f r o m t h e t u b e a n d w i p e c le a n .

a . P u r p o s e . T T h e c o l d c h e c k d e t e r m i n e s i f t h e t r a n s m i s s io n h a s e n o u g h fl u id t o b e o p e r a t e d s a f e l y u n til a h o t c h e c k c a n b e m a d e . C A U T I O N : T T h e fl u i d l e v e fl u id t e m p e r a tu r e r is e s . D a b o v e “C O L D C H E C K ” b tr a n s m is s io n fl u i d is b e lo w te m p e r a t u r e s . D u r in g o p e t r a n s m i s s io n c a n b e c o m e le a d i n g t o t r a n s m is s io n d a

t id le ( 5 0 0 – 8 0 . S h i f t t o D D ( D c le a r t h e h y d t o N N ( N e u t r a l ) a t id le ( 5 0 0 – 8


( F ig u r e 2 – 1 ) p e r f o r m in g t h e H o t C h e c k id m u s t b e a t o p e r a t in g s u r e o f a n a c c u r a t e c h e c k t r a n s m i s s io n d a m a g e . e s a s t e m p e r a t u r e o p e r a t i o n , a n o v e r f u l l b e c o m e o v e r h e a t e d is s io n d a m a g e .

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M A I N T E N A N C E 5 . I f t h e fl u id le v e b a n d , a d d o r d fl u id le v e l to w l e v e l is w i t h in d ip s t ic k ( r e f e r

2 – 9 .

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l is r a in it h in th e to F

n o t w a s n th e “H O T ig u r e

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ith in t h e c e s s a b a n d . S R U N ” 2 – 1 ) .

2 – 1 0 .

F i g u r e 2 – 1 . F l u i d D i p s t i c k M a r k i n g s a .

H o t C h e c k P r o c e d u r e . 1 . O p e r a t e t h e t r a n s m i s s i o n i n D D ( D r i v e ) r a n g e u n t i l n o r m a l o p e r a t in g t e m p e r a t u r e i s r e a c h e d : • S u m p te m p e ra tu re — ( 1 6 0 – 2 0 0 ° F )

7 1 – 9 3 ° C

• C o n v e r te r -o u t te m p e ra tu r e — ( 1 8 0 – 2 2 0 ° F ) . If a p re w a th e lo a

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i c le o n a le v e l s u r f a c e a n d s h i f t l ) . A p p l y t h e p a r k in g b r a k e a n d e e ls . A llo w t h e e n g i n e t o i d l e m ) .

3 . W i t h t h e e n g i n e r u n n i n g , r e m o v e t h e d i p s t i c k f r o m t h e t u b e a n d w i p e c le a n . 4 . I n s e r t t h e d i p s t i c k i n t o t h e t u b e u n t i l i t s t o p s a n d r e m o v e . C h e c k fl u id l e v e l. R e p e a t t h e c h e c k p r o c e d u r e t o v e r if y t h e r e a d i n g .

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C A U T I O N : C C o n t a i n e r s o r h a v e b e e n u s e d fo r a n t if r e c o o la n t s o lu t i o n m u s t N E V tr a n s m is s io n fl u i d . A n t if r e e s o lu t io n s c o n ta in e t h y le n e p u t i n t o t h e t r a n s m is s io n , c p l a t e f a i l u r e . P r tra L a tra

e “ ry a f b a

fi l l e r s t h a t e z e o r e n g in e E R b e u s e d f o r z e a n d c o o l a n t g l y c o l w h i c h , i f a n c a u s e c l u t c h

e i g n m a t e r i a l f r o m e n t e r i n g t h e n b y u s i n g c l e a n c o n t a i n e r s , fi l l e r s , e t c . s t i c k i n a c l e a n p l a c e w h i l e fi l l i n g t h e n .

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R E C O M M E N D A T IO N S

N O T E : E f f e c t i v e M o t o r s n o lo n g e r fl u id s . F lu id s p e c g iv e s O E M s a n d a p p r o v e d fl u id c h th e s a m e fl u id a n th e fo rm e r D E X R

J a n lic ifi c c u o ic d fi O N

u a r y 1 , 2 0 0 7 , G e n e r a l e n s e s D E X R O N - I I I ® a t i o n T E S 3 8 9 fl u i d s t o m e r s a n o t h e r e . T E S 3 8 9 fl u id s h a v e lt e r c h a n g e in t e r v a ls a s - I I I ® .

C A U T I O N : B B e g i n n i n g w i t h S / N 6 5 1 0 7 1 7 2 8 1 , S / N 6 5 2 0 0 8 3 0 9 3 , S / N 6 6 1 0 2 2 0 9 9 0 , S / N 6 6 2 0 0 0 5 8 2 1 , S / N 9 3 7 0 0 0 7 6 6 1 , S / N 9 3 2 0 0 0 6 2 3 1 , S / N 9 4 7 0 0 0 6 0 8 0 , a n d S / N 9 4 2 0 0 0 7 5 6 0 , m a t e r ia l o f s p e c i fi c s e a l s h a s b e e n m o d i fi e d t o b e c o m p a t i b l e w i t h D E X R O N - V I ® fl u i d s . T r a n s m is s io n s p r io r t o t h e a b o v e s e r ia l n u m b e r s a r e n o t c o m p a t ib l e w i t h D E X R O N - V I ® fl u i d s . S e a l c o m p a t i b i l i t y c a n b e id e n tifi e d b y a " D 6 C " o r 8 c o lo r m a r k s o n t h e f a c e o f t h e s e a l. S e e S I L 6 - W T - 0 7 f o r m o r e in f o r m a t io n . a . T h e h y d r a u l i c fl u i d s ( o i l s ) u s e d i n A l l i s o n t r a n s m i s s i o n s d i r e c t l y a f f e c t t r a n s m i s s i o n p e r f o r m a n c e , r e l i a b i l i t y , a n d d u r a b i l i t y . U s e a n


2 - 5


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A l l i s o n a p p r o v e d T E S 2 9 5 fl u i d , D E X R O N - V I ® , o r T E S 3 8 9 f o r r e g u l a r d u t y , o n - h ig h w a y a p p l i c a t i o n s .

2 – 1 1 .

b . T o v e r if y y o u r fl u i d is q u a lifi e d f o r u s e in A l l i s o n t r a n s m i s s i o n s , c h e c k f o r a n A l l i s o n a p p r o v e d T E S 2 9 5 l a b e l , a D E X R O N - V I ® , o r a T E S 3 8 9 fl u id lic e n s e , o r a p p r o v a l n u m b e r o n t h e fl u i d c o n t a i n e r , o r c o n s u l t t h e l u b r i c a n t m a n u f a c t u r e r . C o n s u l t y o u r A l l i s o n T r a n s m i s s i o n d e a l e r o r d i s t r i b u t o r b e f o r e u s i n g a n y fl u i d t y p e s e x c e p t t h o s e fl u i d s q u a l i fi e d f o r u s e i n A l l i s o n t r a n s m i s s i o n s .

h e n c h o o s in g t h e o p t im u m v is c o s it y g r a d e f fl u id t o u s e , t a k e d u t y c y c le , p r e h e a t a p a b i l i t i e s , a n d / o r g e o g r a p h i c a l l o c a t i o n i n t o o n s i d e r a t i o n . T a b l e 2 – 5 l i s t s t h e m i n i m u m u i d t e m p e r a t u r e s a t w h i c h t h e t r a n s m i s s i o n a y b e s a f e l y o p e r a t e d . P r e h e a t w it h u x i l i a r y h e a t i n g e q u i p m e n t o r b y r u n n i n g t h e q u i p m e n t o r v e h i c l e w i t h t h e t r a n s m i s s i o n i n e u t r a l f o r a m in i m u m o f 2 0 m in u t e s b e f o r e t t e m p t i n g r a n g e o p e r a t i o n .

S A E V i s c o s i t y M i n i m u m O p e r a t i n g T e m p e r a t u r e G r a d e * O r F l u i d D e g re e s (C ) D e g r e e s ( F ) T y p e -3 2

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o c a l c y c le m h a n g e e c o m m ra n s m h a n g e f fl u id e c o m m

S A E “ W ” d e s i g n a t io n m e a n s w i n t e r w e i g h t b a s e d o n c o ld t e m p e r a t u r e p r o p e r t i e s .

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a n g e s . I I f u s i n g g o fi lte r a f t e r t h e fi r s t 8 th e re c o m m e n d e d ls in T a b le 2 – 6 . T a b g u i d e f o r fl u id a n d

l d s e r i e s 0 0 0 k m fl u id l e 2 – 6 i s fi lt e r

o n d i t i o n s , s e v e r i t y o f o p e r a t i o n , o r d u t y a y r e q u i r e m o r e o r le s s f r e q u e n t fl u i d i n t e r v a l s t h a t d i f f e r f r o m t h e p u b l i s h e d e n d e d fl u i d c h a n g e i n t e r v a l s o f A l l i s o n i s s i o n . T r a n s m i s s i o n p r o t e c t i o n a n d fl u i d i n t e r v a ls c a n b e o p t im i z e d b y t h e u s e a n a l y s is . C h a n g e fi l t e r s a t o r b e f o r e t h e e n d e d in t e r v a ls . R e f e r t o S I L 1 0 - T R - 9 9 .

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b . H i g h C a p a c i t y F i l t e r s . A l l i s o n 3 0 0 0 P r o d u c t F a m i l i e s t r a n s m i s s i o n h i g h c a p a c i t y fi l t e r s w e r e r e l e a s e d in t o p r o d u c t io n b e g i n n in g J u l y 2 0 0 6 . H i g h c a p a c i t y fi l t e r s a l l o w e x t e n d e d fi l t e r c h a n g e i n t e r v a l s w h e n u s e d w it h a n A llis o n a p p r o v e d T E S 2 9 5 fl u i d . H i g h c a p a c it y fi l t e r s c a n b e i d e n t i fi e d b y P / N 2 9 5 4 5 7 7 7 o r 2 9 5 4 5 7 8 0 s ta m p e d in t o t h e fi lt e r e n d c a p . P r e v i o u s A llis o n 3 0 0 0 P r o d u c t F a m i l i e s t r a n s m i s s i o n fi l t e r s c a n b e i d e n t i fi e d b y P / N 2 9 5 3 8 2 3 1 o r 2 9 5 3 8 2 3 2 s t a m p e d i n t o t h e fi lt e r e n d c a p . W h e n r e p l a c i n g g o l d s e r ie s fi lt e r s w i t h h i g h c a p a c i t y fi l t e r s i n t r a n s m i s s i o n s c o n t a i n i n g 1 0 0 p e r c e n t A llis o n a p p r o v e d T E S 2 9 5 fl u i d , it i s a l l o w e d t o f o l l o w h i g h c a p a c i t y fl u i d a n d fi l t e r c h a n g e i n t e r v a l s . R e f e r t o T a b le 2 – 6 .

T a b l e 2 – 5 . T r a n s m i s s i o n F l u i d O p e r a t i n g T e m p e r a t u r e R e q u i r e m e n t s

M IL -P R F -4 6 1 6 7

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C A U T I O N : T r a n s m i s s i o n fl u i d a n d fi l t e r c h a n g e f r e q u e n c y is d e t e r m in e d b y t h e s e v e r i t y o f t r a n s m i s s i o n s e r v i c e . M o r e f r e q u e n t c h a n g e s m a y b e n e c e s s a r y t h a n r e c o m m e n d e d in t h e g e n e r a l g u id e l in e s w h e n o p e r a t i n g c o n d i t i o n s c r e a t e h i g h l e v e l s o f c o n t a m i n a t i o n o r o v e r h e a t i n g .

C A U T I O N : D i s r e g a r d i n g m i n i m u m fl u i d t e m p e r a t u r e l i m i t s c a n r e s u l t i n t r a n s m i s s i o n m a l f u n c t i o n o r r e d u c e d t r a n s m i s s i o n l i f e . c . W o c c fl m a e n a

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P R O G N O S T I C S b N O T E : I f p r o g n o s t i c s i s t u r n e d o f f o r n o t c a l i b r a t e d i n t h e T C M , u s e o f h i g h c a p a c i t y fi l t e r a n d fl u i d c h a n g e i n t e r v a l s m u s t b e f o l l o w e d .

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p r o g n o s t ic s s fi r s t. A l s o p a c i t y fi l t e r s o n ) .

N O T E : C h a n g e fl u i d / fi l t e r s a t o r b e f o r e r e c o m m e n d e d m i l e a g e , m o n t h s , o r h o u r s h a v e e l a p s e d , w h i c h e v e r o c c u r s fi r s t . N O T E : L o c a l c o n d i t i o n s , s e v e r i t y o f o p e r a t i o n o r d u t y c y c l e m a y r e q u i r e m o r e o r l e s s f r e q u e n t fl u i d c h a n g e i n t e r v a l s t h a t d i f f e r f r o m t h e p u b l i s h e d r e c o m m e n d e d fl u i d c h a n g e i n t e r v a l s . I n t h e a b s e n c e o f a fl u i d a n a l y s is p r o g r a m , t h e fl u i d c h a n g e i n t e r v a l s l i s t e d i n t h e c h a r t s a b o v e s h o u l d b e u s e d . N O T E : G e n e r a l V o c a t i o n : I n t e r c i t y C o a c h w i t h d u t y c y c l e l e s s t h a n o r e q u a l t o o n e s t o p p e r m i l e a n d a l l o t h e r v o c a t i o n s n o t l i s t e d i n s e v e r e v o c a t i o n . N O T E : S e v e r e V o c a t i o n : A l l R e t a r d e r s , O n / O f f H i g h w a y , R e f u s e , T r a n s i t , S h u t t l e T r a n s i t , 2 0 0 0 M H , a n d I n t e r c i t y C o a c h w i t h d u t y c y c l e g r e a t e r t h a n o n e s t o p p e r m ile . a b

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c . F l u i d A n a l y s is . O p t im p r o t e c t io n a n d fl u id c h a n g e fl u id o x id a tio n a c c o r d in g t o s h o w n in T a b le 2 – 7 . C o n s u d i r e c to r y f o r fl u id a n a l y s is fi a c c u r a t e fl u i d a n a l y s is , u s e fi r m . R e f e r t o t h e T e c h n ic ia T r a n s m is s io n F l u id , G N 2 0 5 f o r a d d i t i o n a l i n f o r m a t i o n .

i z e t r a n s m i s s i o n i n t e r v a l s b y m o n i t o r i n g t h e t e s t s a n d l i m i t s l t y o u r lo c a l t e l e p h o n e r m s . F o r c o n s i s t e n t a n d o n l y o n e fl u i d a n a l y s i s n ’ s G u i d e f o r A u t o m a t i c 5 E N , o r S I L 1 7 – T R - 9 6

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T r a n s m i s s io n fl u i d i n t h e w a t e r s id e o f t h e c o o l e r ( h e a t e x c h a n g e r ) i s a n o t h e r s i g n o f a l e a k . N O c o lo c c o b g r a m c v c g c

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: U p o n d i s c o v e r i n m in a t io n , if t h e r e t o t a l c le a n - u p o f e c o o le r . C o n t a m in t h e c o o le r c a n i s s i o n fl u i d .

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u id c h a n g e , e x a m i n e t h e d r a i n e d v id e n c e o f d i r t o r w a t e r . A n o r m a l f c o n d e n s a t io n w i ll a p p e a r i n t h e fl u i d e r a t i o n . w a te r c o n ta m s io n fl u id r e q u te s t in g th e c o b e t w e e n t h e

in a t io n o f ir e s in s p e c o le r ( h e a t w a t e r a n d

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e t a l d , r e p l a c e in s p e c t a l l n .

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t h e t i n g a n d e x c h a n g e r ) fl u id a r e a s .

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e x c e s s h a s o c a n d v is e tra n s m

V i s i b l e m e t a l p a r t i c l e s i n t h e t r a n s m i s s i o n fl u i d ( e x c e p t f o r t h e m i n u t e p a r t i c l e s n o r m a l l y t r a p p e d i n t h e o i l fi l t e r ) m a y i n d i c a t e i n t e r n a l t r a n s m i s s i o n d a m a g e . W h e n t h e s e p a r t i c le s a r e f o u n d i n t h e s u m p , t h e t r a n s m i s s i o n m m u s t b e d i s a s s e m b l e d a n d c lo s e ly in s p e c t e d t o fi n d t h e s o u r c e . M e t a l c o n t a m i n a t i o n r e q u i r e s c o m p l e t e t r a n s m i s s i o n d i s a s s e m b l y . C le a n a l l i n t e r n a l a n d e x t e r n a l h y d r a u l i c c i r c u i t s , c o o l e r , a n d a l l o t h e r a r e a s w h e r e t h e p a r t i c l e s c o u l d l o d g e .

2 – 1 3 .

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r w a t e r c a n a ls o b e b y e n g i n e o il. B e s u r e t o r e c t s o u r c e o f c o o l e r w a t e r .

o f fl u id .

C A U T I O N : T r a n s m i s s i o n fl u i d a n d fi l t e r s m u s t b e c h a n g e d w h e n e v e r t h e r e is e v i d e n c e o f d i r t o r a h i g h t e m p e r a t u r e c o n d i t i o n . A h i g h t e m p e r a t u r e c o n d i t i o n i s i n d i c a t e d w h e n t h e t r a n s m i s s i o n fl u i d is d i s c o lo r e d , h a s a s t r o n g o d o r o r h a s e x c e e d e d o i l a n a l y s is l i m i t s s h o w n i n T a b le 2 – 6 .

a .

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E n g i n e C o o l a n t . E n g i n e c o o l a n t ( e t h y l e n e l y c o l ) i n t h e t r a n s m i s s i o n h y d r a u l i c s y s t e m e q u i r e s i m m e d i a t e a c t i o n t o p r e v e n t m a l f u n c t i o n n d p o s s i b l e s e r i o u s d a m a g e . T h e t r a n s m i s s io n u s t b e c o m p l e t e l y d i s a s s e m b l e d , i n s p e c t e d , a n d le a n e d . R e m o v e a l l t r a c e s o f t h e c o o la n t a n d a r n i s h d e p o s i t s r e s u l t i n g f r o m e n g i n e c o o l a n t o n t a m i n a t i o n . R e p l a c e f r i c t i o n c l u t c h p l a t e s , s e a l s , a s k e t s , a n d b e a r i n g s c o n t a m i n a t e d w i t h e n g i n e o o l a n t .

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n t a c t w it h th e a in in g tr a n s m ith th e h o t fl u in b o d ily in ju r

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4 . I n s t a ll s ix M 1 0 x 1 . 5 x 1 0 0 b o l t s ( 6 ) in t o e a c h c o v e r ( 5 ) a n d t ig h t e n t h e m t o 5 1 – 6 1 N ∙ m ( 3 8 – 4 5 l b f t ) .

h o t fl u i d i s s io n i d o r t h e y .

fl u id w h e n t h e fl u id t u r e — 7 1 – 9 3 ° C fl o w s q u i c k e r a n d .

o r a ll m o d e ls e x c e p t 3 7 0 0 S P , r e m lu g a s s e m b ly ( 9 ) ( F ig u r e 2 – 2 ) fr o m o n t r o l v a lv e m o d u le a n d a llo w th e r a in in t o a s u it a b l e c o n t a in e r. F o r a e m o v e d r a in p lu g a s s e m b lie s ( 7 ) a F ig u r e 2 – 3 ) f r o m th e c o n t r o l v a lv e n d tr a n s fe r c a s e . A llo w th e fl u id to u i t a b l e c o n t a i n e r s .

o v e d r a in t h e fl u id t o 3 7 0 0 S P , n d ( 1 0 ) m o d u l e d r a i n i n t o

3 . E x a m in e t h e fl u id a s d e s c r ib e d in 2 – 1 2 . F L U I D C O N T A M I N A T IO N . b .

R e p l a c e F i l t e r s ( F i g u r e 2 – 2 ) . C A U T I O N : D o n o t i n t e r c h a n g e t h e d e e p a n d s h a l l o w s u m p fi l t e r s . I n s t a l l a t i o n o f t h e w r o n g fi lt e r c a n c a u s e d a m a g e t o t h e t r a n s m i s s i o n . 1 . T o r e p la t w o fi lt e O - r in g s fro m th e

c e th e r c o v e (3 ) , tw b o tto

o i l fi lt e r s , r s (5 ) , tw o o O O - r i n g s m o f th e c

2 . W h e n in s t a l lin g p a r ts O - r in g ( 2 ) a n d ( 3 ) o n t h e O - r i n g i n s i d e t t h e o n to e a c h c o v e r (5 ). o n e a c h c o v e r (5 ) a n g a s k e t w it h h o l e s in

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m o v e a s k e ts ), a n d tro l v a

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lt s ( 6 ) , t w o l t e r s ( 1 ) o d u l e .

n d in s t a (5 ). L u b d p u s h g a s k e t h o le s in

l l n e w r ic a t e fi lt e r ( 4 ) t h e

C A U T I O N : D o n o t u s e t h e b o l t s t o d r a w fi lt e r c o v e r s t o t h e s u m p . T h i s c a n d a m a g e t h e c o v e r s , s e a l s , o r s u m p . 3 . In s t a ll fi lte t h e fi lt e r c a s s e m b ly p la te /s u m fi lte r /c o v e

r ( o m to p . r a

1 ) a n d c o p a rtm e n t h e h o le S e a t th e s s e m b lie

v e r t. In s in s e a s in

(5 ) a s s d e x e a th e c h ls b y p b y h a n

e m b l i e s i n t o c h fi l t e r / c o v e r a n n e l u s h i n g t h e d .

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c . R e p la c e F ilte r s — ( F i g u r e 2 – 3 ) . C A U a n d th e tra n

3 7 0 0 S P

T r a n s m i s s io n

T I O N : D o n o t i n t e r c h a n g e t h e d e e p s h a l l o w s u m p fi l t e r s . I n s t a l l a t i o n o f w r o n g fi lt e r c a n c a u s e d a m a g e t o t h e s m i s s i o n .

1 . T o r e p la c e t h e o i l fi lt e r s , r e m o v e 1 2 b o lt s ( 6 ) , t w o fi lt e r c o v e r s ( 5 ) , t w o g a s k e t s ( 4 ) , t w o O - r in g s ( 3 ) , a n d t w o O - r in g s ( 2 ) . 2 . W h e O - r in O - r in o n to th e h

n in s t a g s (2 ) g in s id c o v e r o le s w

llin g p a r ts a n d (3 ) o e t h e fi lte (5 ) . In s ta ith th o s e


, l u b r i c a t e a n d i n s t a l l n e w n c o v e r ( 5 ) . L u b r ic a t e r ( 1 ) a n d p u s h t h e fi l t e r l l n e w g a s k e t a n d a l ig n in t h e c o v e r ( 5 ) .

2 - 9

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M A N U A L — 3 0 0 0 P r o d u c t F a m i l y — A l l i s o n 4 t h G e n e r a t i o n C o n t r o ls — V O C A T IO N A L M O D E L S r 3 p r (

C A U T I O N : D o n o t u s e t h e b o l t s t o d r a w fi lt e r c o v e r s t o t h e s u m p . T h i s c a n d a m a g e t h e c o v e r s , s e a l s , o r s u m p . 3 . In s ta ll fi lte th e fi lte r c a s s e m b ly p la te /s u m fi lte r /c o v e

r (1 ) a n d c o v o m p a rtm e n t. t o t h e h o le s p . S e a t th e s r a s s e m b lie s

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(5 ) a s s d e x e a th e c h ls b y p b y h a n

e p la 7 0 0 lu g e p la 1 2 )

e m b l i e s i n t o c h fi l t e r / c o v e r a n n e l u s h i n g t h e d .

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4 . I n s t a ll s ix M 1 0 x 1 . 5 x 1 0 0 b o l t s ( 6 ) in t o e a c h c o v e r ( 5 ) a n d t ig h t e n t h e m t o 5 1 – 6 1 N ∙ m ( 3 8 – 4 5 l b f t ) .

r in g ( 7 ) o d e ls , b lie s ( r in g s ( ( u i r e d .

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h e n e v e r m e n o r m a lly n p lu g ( 1 2 a s e to fi n d t a m in a t io n

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r t i c l e s , l a r g e r fi l t e r s , a r e m b l e t h e i r t h e s o u r c e

2 . T ig h t e n d r a in p lu g s to 2 5 – 3 2 N ∙m a f t e r i n s p e c t i o n i s c o m p l e t e d . 3 . A fte r re to P a ra ( F ig u r e P ro c e d N c fi r w

. F o r a in ) a n d a n d

( 1 8 – 2 4 lb f t )

fi l l , c h e c k t h e fl u i d l e v e l ( r e f e r g r a p h s 2 – 7 . C O L D C H E C K 2 – 1 ) a n d 2 – 8 a . H o t C h e c k u r e ) .

O T E : W h o m p le te ly lt e r s o r fl u e m a i n s in ill b e le s s

e n th e tra d is a s s e m id is c h a n th e tra n s m th a n fo r a

n s m is s io n b le d o r w h g e d , s o m e is s io n s o r d r y u n i t .

is n o t e n ju s t fl u id e fi l l q u a n t i t y

4 . R e f e r t o T a b l e 2 – 8 f o r t y p i c a l i n i t i a l fi l l ( d r y u n i t ) a n d f o r fl u i d a m o u n t s r e q u i r e d t o fi fi l l c o o l e r s a n d t h e r e m o t e r e t a r d e r a c c u m u l a t o r . T a b le 2 – 8 . F lu id Ite m

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C A U T I O N : T T h e s e a l m a t e r i a l i n t r a n s m i s s i o n s b e g i n n i n g w i t h t r a n s m i s s i o n S / N 6 5 1 0 7 1 7 0 7 5 h a s b e e n c h a n g e d t o b e c o m p a t i b l e w i t h D E X R O N – V I ® fl u i d s . D O N O T u s e D E X R O N – V I ® i n t r a n s m i s s i o n w i t h e a r l i e r s e r i a l n u m b e r s .

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1 . F o r a ll m o d e ls e x c e p t t h e 3 7 0 0 S P , in s p e c t d r a i n p l u g a s s e m b l y ( 9 ) ( F ig u r e 2 – 2 ) a n d 2 - 1 0

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0 .9 L ( 0 . 9 5 q t)

P R E V E N T IV E 2 – 1 4 . a . L o o n to p s e rv e s tra n s m b .

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tio n th e p re io n

a n d P tra n s m v e n t a a n d m m

u r p o s e . T T is s io n c o n ir p r e s s u re u s t b e k e p

h e b re v e rte r b u ild u t c le a

a th e r is h o u s in g p w ith in n a n d o p

l o c a t e d . I t t h e e n .

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A U T I O N : B e s u r e ttin g s h a v e t h e s a m e m o v e d ( 7 ∕1∕1 6 - 2 0 U e s t r a ig h t th r e a d , O o th is w ill r e s u l t in a lv e m o d u l e .

th a t th e h y d r a e th r e a d a s th N F - 2 A ) . F it tin g - r in g s t y le . F a d a m a g e to th e

u l ic e p l u g s s m u s t i l u r e t o c o n t r o l

M a in t e n a n c e . 1 . T h e d e te U s e e x te s o lu th e tra n

a m o u n t o f d u s t a n d d ir t e n c o u n t e r e d r m i n e s t h e f r e q u e n c y o f b r e a t h e r c l e a n i n g . c a r e w h e n c le a n i n g t h e t r a n s m i s s io n r i o r . S p r a y i n g s t e a m , w a t e r , o r c l e a n i n g t i o n d i r e c t l y a t t h e b r e a t h e r c a n f o r c e w a t e r o r c l e a n i n g s o l u t i o n i n t o t h e s m i s s i o n .

2 . A lw a y s u s e a p r o p e r ly o r r e p la c e th e b r e a th e w re n c h c a n c ru s h o r d p r o d u c e m e ta l c h ip s w t r a n s m i s s i o n .

2 – 1 5 .

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s iz e r. P a m a h ic h

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th e re s ) s e is s io n to m a s u r in g t b e e n

re n c h to r s o r a p ip th e s te m u ld e n t e r

e m o v e e a n d t h e

P R E S S U R E S

M e a s u r in g in d iv id u a l c lu t c h p r e s s u r d e t e r m in e if a t r a n s m is s io n m a l f u n c a m e c h a n ic a l o r a n e le c t r ic a l p r o b l e m a k in g th e s e p r e s s u r e m e a s u r e m e t r a n s m is s io n a n d v e h ic le ( o r te s t s t a r e c o r d in g o f d a t a , a n d c o m p a r in g r e a g a in s t s p e c ifi c a tio n s p r o v id e d . T h e a r e f o r a ll 3 0 0 0 P r o d u c t F a m ilie s t r a

a .


e s h e l p s t i o n i s d u e t o m . P r o p e r l y n t s r e q u ir e s n d ) p r e p a r a t i o n , c o r d e d d a t a s e i n s t r u c t i o n s n s m is s io n s .

2 . I n s t a l l h y d r a u l i c fi t t i n g s s u i t a b l e f o r a t t a c h i n g p r e s s u r e g a u g e s o r t r a n s d u c e r s . 3 . C o n n e c t p r P re s s u re G is a v a ila b le T a b le 2 – 9 T a b le 2 – 1 0

e s s u r e g a u g e s o r t r a n s d u c e r s . a u g e S e t P / N J – 2 6 4 1 7 - A f o r t h i s p u r p o s e . R e f e r t o f o r t e s t c o n d i t io n s a n d t o f o r p r e s s u r e le v e l s e x p e c t e d .

4 . B e s u r e t h e e n g in e s p e e d c a n b e m o n it o r e d . ( A l l i s o n D O C ® F o r P C – S e r v i c e T o o l m a y b e u s e d f o r t h i s p u r p o s e . ) 5 . B e te m F o p u

s u re p e ra r P C – rp o s e

t h e t r a n s m i s s io n s u m p fl u i d t u r e c a n b e m e a s u r e d . ( A l l i s o n D O C ® S e r v ic e T o o l m a y b e u s e d f o r t h i s . )

6 . B e s u r e t h e t r a n s m is s io n h a s e n o u g h fl u id f o r c o l d o p e r a t i o n u n t i l a n o p e r a t i n g t e m p e r a t u r e fl u id le v e l c a n b e s e t . 7 . B r in te m In s p g a u n e e

g th e tra n s m p e ra tu re o f e c t fo r fl u id g e /tra n s d u c d e d . B e s u r

is s io n t o n o r m a 7 1 – 9 3 º C (1 6 0 – 2 le a k s in t h e a d d e r lin e s . R e p a ir e t h a t fl u i d le v e l

l o p e r a t in g 0 0 º F ) . e d p r e s s u r e l e a k s a s i s c o r r e c t .

a r e D i a g n o s t i c t w h ic h a r e d i f fi c u l t y y o u a r e k e m e c h a n ic a l c l u t c h p r e s s u r e s e v a lu a t e d .

T r a n s m i s s i o n a n d V e h i c l e P r e p a r a t i o n . 1 . R e m o v e t h e p lu g s f r o m t h e p r e s s u r e t a p l o c a t i o n s w h e r e t h e m e a s u r e m e n t i s d e s i r e d ( r e f e r t o F ig u r e 2 – 4 ) .

C o p y r ig h t ©

2 0 0 9


2 - 1 1

S E R V IC E


N O T E : M e a s u r e l o c k u p c l u t c h p r e s s u r e b y d r i v i n g t h e v e h i c l e i n a r a n g e w h e r e l o c k u p c a n b e o b t a i n e d . R e c o r d t h e p r e s s u r e v a lu e s a t t h e e n g i n e s p e e d a n d s u m p fl u id t e m p e r a t u r e v a lu e s s h o w n in T a b le 2 – 9 . T h e l o c k u p c l u t c h i s f u n c t i o n i n g c o r r e c t l y w h e n e n g in e s p e e d a n d t u r b in e s p e e d v a lu e s a r e e q u a l a s r e c o r d e d f r o m t h e A l l i s o n D O C ® F o r P C – S e r v i c e T o o l . 2 . R e f e r t o T a b l e 2 – 9 a n d l o c a t e t h e t r a n s m i s s io n m o d e l t h a t y o u a r e t e s t in g . 3 . O p e s h o tra n h y d th e c .

r a t w n s m ra u ra n

e th e tra n s m in T a b le 2 – 9 is s io n s u m p lic p r e s s u r e , g e s w h e re a

is a fl a p

s io n d u id n d ro b

n a t th re c o rd te m p e c lu t c h le m is

e c o n d it io n e n g in e s p ra tu re , m a p re s s u r e s s u s p e c te d

s e e d , i n i n .

C o m p a r i n g R e c o r d e d D a t a t o S p e c ifi c a t i o n s . 1 . B e s u r e t h e e n g in e s p e e d a n d t r a n s m is s io n s u m p fl u i d t e m p e r a t u r e s a r e w i t h i n t h e v a l u e s s p e c ifi e d in T a b l e 2 – 9 . 2 . C o m p a r e t h e m a in p r e s s u r e a n d c lu t c h p r e s s u r e d a t a r e c o r d e d in 2 – 1 5 b . R e c o r d i n g D a t a , w i t h t h e s p e c ifi c a t io n s in T a b le 2 – 1 0 .

F i g u r e 2 – 4 . C l u t c h P r e s s u r e C h e c k P o i n t s b .

R e c o r d i n g D a t a . 1 . T h e A l l i s o n D O C ® F o r P C – S e r v i c e T o o l a l l o w s c h e c k i n g o f i n d i v i d u a l r a n g e c l u t c h p r e s s u r e s w i t h t h e v e h i c l e s t a t i o n a r y . C l u t c h T e s t i n s t r u c t i o n s a r e l o c a t e d i n t h e A c t i o n R e q u e s t s e c t i o n o f t h e A l l i s o n D O C T M F o r P C – S e r v ic e T o o l U s e r G u id e , G N 3 4 3 3 E N . F o l l o w i n s t r u c t i o n s t o c h e c k c l u t c h p r e s s u r e s i n i n d i v i d u a l r a n g e s .

2 - 1 2

C o p y r ig h t ©

3 . If c lu t c h re tu r n th o r ig in a l e le c t r ic a

p r e s s u re s a r e w e tr a n s m is s io n c o n fi g u r a t io n a n l t r o u b le s h o o t in

4 . If c ta k p a th e

p re re c th e le m

lu e rts p

tc h c o r o f ro b

i t h i n s p e c i fi c a t i o n s , a n d v e h i c l e t o t h e i r d p r o c e e d w i t h g .

s s u r e s a r e n o t w i t h i n s p e c i fi c a t i o n , t i v e a c t i o n t o r e p l a c e t h e i n t e r n a l t r a n s m i s s i o n n e c e s s a r y t o c o r r e c t .

5 . M e a s u r e p r e s s u r e v a lu e s a f t e r t h e t r a n s m is s i o n h a s b e e n r e p a i r e d . 6 . R c a p b (

e t u r n t h e t r a n s m is s i o n t o it s o r ig i n a l o n fi g u r a t i o n . ( R e m o v e i n s t r u m e n t a t i o n n d in s t a ll a n y c o m p o n e n t s r e m o v e d f o r r e s s u r e t e s t i n g . P r e s s u r e t a p p l u g s s h o u l d e r e i n s t a l l e d a n d t i g h t e n e d t o 1 0 – 1 3 N ∙ m ; 7 – 1 0 l b f t . ) .


P R E V E N T IV E T a b le 2 – 9 . C lu t c h T r a n s m i s s i o n M o d e l / T e s t T y p e 3 0 0 0 F a m ily —

P r o d u c t I d l e C h e c k

E n g in e

r p m

5 8 0 – 6 2 0

3 0 0 0 P r o d u c t F a m ily — H ig h S p e e d

2 0 8 0 – 2 1 2 0


2 0 8 0 – 2 1 2 0

3 7 0 0

S P — H i g h S p e e d

P r e s s u r e T e s t C o n d i t i o n s

S u m p F lu id T e m p

R a n g e

7 1 – 9 3 º C ( 1 6 0 – 2 0 0 º F )

N ( N e u t r a l ) R ( R e v e r s e ) L o w C 1 C

C 5 C 3 C 5 C 3 C 6 C 1 C 5

7 1 – 9 3 º C ( 1 6 0 – 2 0 0 º F )

R ( R e v e r s e ) N ( N e u t r a l ) 1 C 2 C

C 3 C 5 C 5 C 1 C 5 C 1 C 4

2 3 4 5 6

2 0 8 0 – 2 1 2 0

C o p y r ig h t ©


L L L L L

R ( R e v e r s e ) N ( N e u t r a l ) C 5 L o C 1 C 2 C 2 L 3 L 4 L 5 L 6 L

2 0 0 9


C l u t c h e s P r e s s u r i z e d

C C C C C

1 1 1 2 2

C C C C C

4 3 2 3 4

L L L L L

U U U U U

C C C C C

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

2 - 1 3

2 1- 4

T a b le 2 – 1 0 . M a i n P r e s s u r e a n d C l u t c h P r e s s u r e S p e c ifi c a t i o n s ( S u m p F l u i d T e m p e r a t u r e S a m e a s i n T a b le 2 – 5 ) T r a n s m i s s i o n M o d e l / T e s t T y p e

3 0 0 0 P r o d u c t F a m i l y — I d l e

C o p y r gi h t © 2 0 0 9 A ll si o n T ar n s m si s i o n , In c .

E n g in e rp m

5 8 0 – 6 2 0

R a n g e

M a in P r e s s . S p e c k P a ( p s i )

C l u t c h e s A p p l i e d

R a n g e C l u t c h L u b e P r e s s . P r e s s . S p e c S p e c * * k P a ( p s i ) k P a ( p s i )

L C S k

o c lu p e P a

k u p t c h P r e s s . c ( p s i )

D r o p b o x M a in P r e s s . S p e c * k P a ( p s i )

N e u t r a l M a i n M o d O F F

1 5 1 5 – 2 0 3 5 ( 2 2 0 – 2 9 5 )

C 5

1 4 4 0 – 2 0 3 5 ( 2 1 0 – 2 9 5 )

1 0 – 3 5 (1 – 5 )

N A

1 4 4 0 – 2 0 3 5 ( 2 1 0 – 2 9 5 )

N e u t r a l M a i n M o d O N

1 3 1 0 – 1 7 2 5 ( 1 9 0 – 2 5 0 )

C 5

1 2 3 5 – 1 7 2 5 ( 1 8 0 – 2 5 0 )

1 0 – 3 5 ( 1 – 5 )

N A

1 2 3 5 – 1 7 2 5 ( 1 8 0 – 2 5 0 )

R e v e r s e M a in M o d O F F

1 4 5 0 – 2 0 3 5 ( 2 1 0 – 2 9 5 )

C 3 , C 5

1 3 7 5 – 2 0 3 5 ( 2 0 0 – 2 9 5 )

1 0 – 3 5 ( 1 – 5 )

N A

1 3 7 5 – 2 0 3 5 ( 2 0 0 – 2 9 5 )

R e v e r s e M a in M o d O N

1 1 7 0 – 1 5 8 5 ( 1 7 0 – 2 3 0 )

C 3 , C 5

1 0 9 5 – 1 5 8 5 ( 1 6 0 – 2 3 0 )

1 0 – 3 5 ( 1 – 5 )

N A

1 0 9 5 – 1 5 8 5 ( 1 6 0 – 2 3 0 )

L o w C ( 3 0 0 0 1 2 4 0 – 1 7 2 5 7 - S p e e d ) M a i n ( 1 8 0 – 2 5 0 ) M o d O F F

C 3 , C 6

1 1 6 5 – 1 7 2 5 ( 1 7 0 – 2 5 0 )

1 0 – 3 5 (1 – 5 )

N A

1 1 6 5 – 1 7 2 5 ( 1 7 0 – 2 5 0 )

L o w C ( 3 0 0 0 8 7 0 – 1 3 4 0 7 - S p e e d ) M a i n ( 1 2 5 – 1 9 5 ) M o d O N

C 3 , C 6

7 9 5 – 1 3 4 0 ( 1 1 5 – 1 9 5 )

1 0 – 3 5 ( 1 – 5 )

N A

7 9 5 – 1 3 4 0 ( 1 1 5 – 1 9 5 )

1 C M a in M o d 1 2 4 0 – 1 7 2 5 ( 1 8 0 – 2 5 0 ) O F F

C 1 , C 5

1 1 6 5 – 1 7 2 5 ( 1 7 0 – 2 5 0 )

1 0 – 3 5 ( 1 – 5 )

N A

1 1 6 5 – 1 7 2 5 ( 1 7 0 – 2 5 0 )

1 C M a in M o d 8 7 0 – 1 3 4 0 ( 1 2 5 – 1 9 5 ) O N

C 1 , C 5

7 9 5 – 1 3 4 0 ( 1 1 5 – 1 9 5 )

1 0 – 3 5 ( 1 – 5 )

N A

7 9 5 – 1 3 4 0 ( 1 1 5 – 1 9 5 )

2 C M a in M o d 1 2 4 0 – 1 7 2 5 O F F ( 1 8 0 – 2 5 0 )

C 1 , C 4

1 1 6 5 – 1 7 2 5 ( 1 7 0 – 2 5 0 )

1 0 – 3 5 ( 1 – 5 )

N A

1 1 6 5 – 1 7 2 5 ( 1 7 0 – 2 5 0 )

2 C M a in M o d 8 7 0 – 1 3 4 0 ( 1 2 5 – 1 9 5 ) O N

C 1 , C 4

7 9 5 – 1 3 4 0 ( 1 1 5 – 1 9 5 )

1 0 – 3 5 ( 1 – 5 )

N A

7 9 5 – 1 3 4 0 ( 1 1 5 – 1 9 5 )

S E R V CI E M A N U C A o L n — tr o 3 0 sl 0 0 — V P O or C d A u T c t OI N aF A m L il M y— O A D l E li L s S on 4 ht G e n e ar ti o n

T a b l e 2 - 1 0 . M a i n P r e s s u r e a n d C l u t c h P r e s s u r e S p e c i fi c a t i o n s ( S u m p F l u i d T e m p e r a t u r e S a m e a s i n T a b l e 2 – 5 ) ( c o n t ’ d ) T r a n s m i s s i o n M o d e l / T e s t T y p e

E n g in e rp m

R a n g e

M a in P r e s s . S p e c k P a ( p s i )

C l u t c h e s A p p l i e d

R a n g e C l u t c h L u b e P r e s s . P r e s s . S p e c S p e c * * k P a ( p s i ) k P a ( p s i )

L C S k


2 0 8 0 – 2 1 2 0

N e u t r a l M a i n M o d O F F

1 8 0 5 – 2 2 0 5 ( 2 6 0 – 3 2 0 )

C 5 , L U

1 7 3 0 – 2 2 0 5 ( 2 5 0 – 3 2 0 )

1 6 0 – 2 4 0 ( 2 3 – 3 5 )

0 - 5 0 ( 0 - 7 . 3 )

1 7 3 0 – 2 2 0 5 ( 2 5 0 – 3 2 0 )

N e u t r a l M a i n M o d O N

1 4 1 5 – 1 7 2 5 ( 2 0 5 – 2 5 0 )

C 5 , L U

1 3 3 5 – 1 7 2 5 ( 1 9 5 – 2 5 0 )

1 6 0 – 2 4 0 ( 2 3 – 3 5 )

0 - 5 0 ( 0 - 7 . 3 )

1 3 3 5 – 1 7 2 5 ( 1 9 5 – 2 5 0 )

R e v e rs e

1 8 0 5 – 2 2 0 5 ( 2 6 0 – 3 2 0 )

C 3 , C 5 , L U

1 7 3 0 – 2 2 0 5 ( 2 5 0 – 3 2 0 )

1 6 0 – 2 4 0 ( 2 3 – 3 5 )

0 - 5 0 ( 0 - 7 . 3 )

1 7 3 0 – 2 2 0 5 ( 2 5 0 – 3 2 0 )

L o w C ( 3 0 0 0 7 - S p e e d )

1 5 5 0 – 1 9 6 5 ( 2 2 5 – 2 8 5 )

C 3 , C 6

1 4 7 5 – 1 9 6 5 ( 2 1 5 – 2 8 5 )

1 6 0 – 2 4 0 ( 2 3 – 3 5 )

N A

1 4 7 5 – 1 9 6 5 ( 2 1 5 – 2 8 5 )

1 C

1 5 5 0 – 1 9 6 5 ( 2 2 5 – 2 8 5 )

C 1 , C 5 , L U

1 4 7 5 – 1 9 6 5 ( 2 1 5 – 2 8 5 )

1 6 0 – 2 4 0 ( 2 3 – 3 5 )

0 - 5 0 ( 0 - 7 . 3 )

1 4 7 5 – 1 9 6 5 ( 2 1 5 – 2 8 5 )

2 C

1 5 5 0 – 1 9 6 5 ( 2 2 5 – 2 8 5 )

C 1 , C 4 , L U

1 4 7 5 – 1 9 6 5 ( 2 1 5 – 2 8 5 )

1 6 0 – 2 4 0 ( 2 3 – 3 5 )

0 - 5 0 ( 0 - 7 . 3 )

1 4 7 5 – 1 9 6 5 ( 2 1 5 – 2 8 5 )

2 L

1 0 8 0 – 1 3 6 5 ( 1 5 5 – 2 0 0 )

C 1 , C 4 , L U

1 0 0 5 – 1 3 6 5 ( 1 4 5 – 2 0 0 )

1 6 0 – 2 4 0 ( 2 3 – 3 5 )

1 0 0 5 - 1 3 6 5 ( 1 4 5 - 2 0 0 )

1 0 0 5 – 1 3 6 5 ( 1 4 5 – 2 0 0 )

3 C

1 5 5 0 – 1 9 6 5 ( 2 2 5 – 2 8 5 )

C 1 , C 3

1 4 7 5 – 1 9 6 5 ( 2 1 5 – 2 8 5 )

1 6 0 – 2 4 0 ( 2 3 – 3 5 )

N A

1 4 7 5 – 1 9 6 5 ( 2 1 5 – 2 8 5 )

3 L

1 0 8 0 – 1 3 6 5 ( 1 5 5 – 2 0 0 )

C 1 , C 3 , L U

1 0 0 5 – 1 3 6 5 ( 1 4 5 – 2 0 0 )

1 6 0 – 2 4 0 ( 2 3 – 3 5 )

1 0 0 5 - 1 3 6 5 ( 1 4 5 - 2 0 0 )

1 0 0 5 – 1 3 6 5 ( 1 4 5 – 2 0 0 )

4 C

1 5 5 0 – 1 9 6 5 ( 2 2 5 – 2 8 5 )

C 1 , C 2

1 4 7 5 – 1 9 6 5 ( 2 1 5 – 2 8 5 )

1 2 5 – 2 0 0 ( 1 8 – 3 0 )

N A

1 4 7 5 – 1 9 6 5 ( 2 1 5 – 2 8 5 )

4 L

1 0 8 0 – 1 3 6 5 ( 1 5 5 – 2 0 0 )

C 1 , C 2 , L U

1 0 0 5 – 1 3 6 5 ( 1 4 5 – 2 0 0 )

1 2 5 – 2 0 0 ( 1 8 – 3 0 )

1 0 0 5 - 1 3 6 5 ( 1 4 5 - 2 0 0 )

1 0 0 5 – 1 3 6 5 ( 1 4 5 – 2 0 0 )

5 C

1 5 5 0 – 1 9 6 5 ( 2 2 5 – 2 8 5 )

C 2 , C 3

1 4 7 5 – 1 9 6 5 ( 2 1 5 – 2 8 5 )

1 2 5 – 2 0 0 ( 1 8 – 3 0 )

N A

1 4 7 5 – 1 9 6 5 ( 2 1 5 – 2 8 5 )

5 L

1 0 8 0 – 1 3 6 5 ( 1 5 5 – 2 0 0 )

C 2 , C 3 , L U

1 0 0 5 – 1 3 6 5 ( 1 4 5 – 2 0 0 )

1 2 5 – 2 0 0 ( 1 8 – 3 0 )

1 0 0 5 - 1 3 6 5 ( 1 4 5 - 2 0 0 )

1 0 0 5 – 1 3 6 5 ( 1 4 5 – 2 0 0 )

6 C

1 3 4 5 - 1 5 9 0 ( 2 2 0 – 2 9 0 )

C 2 , C 4

1 2 7 0 - 1 5 9 0 ( 1 8 5 - 2 3 0 )

1 2 5 – 2 0 0 ( 1 8 – 3 0 )

N A

1 2 7 0 -1 5 9 0 ( 1 8 5 - 2 3 0 )

6 L

1 0 3 5 – 1 4 1 5 ( 1 5 0 – 2 0 5 )

C 2 , C 4 , L U

9 6 0 – 1 4 1 5 ( 1 4 0 – 2 0 5 )

1 2 5 – 2 0 0 ( 1 8 – 3 0 )

9 6 0 - 1 4 1 5 ( 1 4 0 - 2 0 5 )

9 6 0 – 1 4 1 5 ( 1 4 0 – 2 0 5 )


2 1- 5

*

o c lu p e P a

k u p t c h P r e s s . c ( p s i )

T o p a s s t h i s s p e c ifi c a tio n , m e a s u r e d c lu t c h p r e s s u r e s m u s t b e w it h i n 7 5 k P a ( 1 0 p s i) o f a c t u a l m e a s u r e d m a in p r e s s u r e a n d s t ill b e w it h in t h e m in i m u m m a x im u m v a lu e o f t h i s s p e c ifi c a t io n .

D r o p b o x M a in P r e s s . S p e c * k P a ( p s i )

a n d

P R E V E N T IV E M A IN T E N A N C E

S E R V IC E

2 – 1 6 .

a if e a a m


T R A N S M IS S IO N S T A L L T E S T A N D N E U T R A L C O O L -D O W N C H E C K

.

P u r p o s e . S t a l l t e s t i n g a v e h i c le p e r f o r m a n c e c n g i n e o r tr a n s m is s io n m a t r o u b le s h o o tin g p r o c e d u s ta ll te s t a s a g e n e r a l c h a i n t e n a n c e .

is p o m p lf u n re o e c k

7 . C o n n e c t A l lis o th e v e h ic le d ia a n a c c u ra te ta v e h ic le ta c h o m

e r f o r m e d t o d e t e r m i n e l a i n t is d u e t o a n c t i o n . S t a l l t e s t i n g i s n l y — n e v e r p e r f o r m o r d u r i n g r o u t i n e

8 . In s ta ll th e tra A l l i s o n s u m p

i m u m e n g i n e t f u l l t h r o t t l e o t m o v i n g , o r t , c o m p a r e t h e r q u e c o n v e r t e r l i s h e d b y t h e

ll T t is t io s m

e s to n s is s

tin g b e h a v io n

P re p p e rfo r e b e e s t a ll t

1 1 . T h e v e h ic l e ’ s b r a k e s a r e f u l l y l o c k e d . W A R N I N G : T o h e l p a v o i d p e r s o n a l i n j u r y , s u c h a s b u r n s , f r o m h o t t r a n s m i s s io n fl u id a n d / o r t o h e l p a v o id e q u i p m e n t d a m a g e , d o n o t s t a l l t h e t o r q u e c o n v e r t e r f o r m o r e t h a n t e n s e c o n d s m a x im u m a n d m o n i t o r t r a n s m is s i o n fl u i d t e m p e r a t u r e . I m m e d i a t e l y r e t u r n t h e e n g i n e t o i d l e i f c o n v e r t e r o u t ( t o c o o l e r ) t e m p e r a t u r e e x c e e d s 1 5 0 ° C ( 3 0 0 ° F ) . O p e r a t in g t h e t r a n s m is s io n a t h ig h e n g i n e p o w e r a t t r a n s m i s s i o n s t a l l o r n e a r s t a l l c o n d i t i o n s c a u s e s a r a p i d r i s e i n t h e t r a n s m i s s i o n fl u i d t e m p e r a t u r e . T h e fl u i d i n t h e t r a n s m i s s i o n t o r q u e c o n v e r t e r i s a b s o r b i n g a l l o f t h e e n g i n e p o w e r a n d t h e v e h i c le c o o l in g s y s t e m c a n n o t d i s s ip a t e t h e e x c e s s i v e h e a t lo a d . E x t e n d e d o p e r a t io n u n d e r h i g h h e a t l o a d c o n d i t i o n s c a u s e s t r a n s m i s s i o n a n d c o o li n g s y s t e m d a m a g e , a n d c a n p o s s ib l y f a i l h y d r a u l i c l i n e s c a u s i n g l e a k i n g h i g h t e m p e r a t u r e fl u id .

a r a t i o n . I f a t r a n s m i s s i o n m e d , m a k e s u r e t h e f o l l o w i n g n m a d e b e f o r e c o n d u c t i n g e s t .

1 . T h e m a n u f a c t u r e r c o n c u r s w it h p e r f o r m in g a f u l l - t h r o t t l e t r a n s m i s s i o n s t a l l t e s t . 2 . T h e rp m th a n s p e e

e n g in e p r o g r a m m a b le p a r a m e t e r f o r 0 t r a n s m i s s io n o u t p u t s p e e d i s s e t h i g h e r t h e v a l u e e x p e c t e d a t t r a n s m is s io n s t a l l d .

W A a n d tra n p o s p a r th e k e e

3 . T h e v e h ic l e i s i n a n a r e a i n w h ic h a t r a n s m i s s i o n s t a l l t e s t c a n b e s a f e l y p e r f o r m e d . 4 . M a k e s u r e t h e f u e l c o n t r o l lin k a g e g o e s t o f u l l t h r o t t le a n d d o e s n o t s t ic k w h e n r e l e a s e d . 5 . M a k e s u r e t h e e n g i n e a i r in d u c t io n s y s t e m a n d e x h a u s t s y s t e m h a v e n o r e s t r ic t io n s . 6 . P e r f o r m a c o l d c h e c k o f t h e t r a n s m i s s io n fl u i d le v e l a n d a d ju s t a s n e c e s s a r y .

c .

C o p y r ig h t ©

R N IN G e q u ip m s m is s io itiv e ly p k in g b r a w h e e ls p c le a r

: T o h e l p e n t d a m n s ta ll te r e v e n te d k e , th e s s e c u r e ly o f th e v e

a v a g s t, fro e rv . W h ic

o i d p e r s o n a l i n j u r y e w h ile c o n d u c t in g a t h e v e h i c l e m u s t b e m m o v i n g . A p p l y t h e ic e b r a k e , a n d c h o c k a r n p e r s o n n e l t o l e a n d it s t r a v e l p a t h .

P e r f o r m i n g a T r a n s m i s s i o n S t a l l T e s t . 1 . S t a r t t h e e n g i n e . W h i l e i n N N ( N e u t r a l ) a l l o w t h e t r a n s m i s s io n t o w a r m t o n o r m a l o p e r a t i n g t e m p e r a t u r e : —

2 - 1 6

r e g a u g e w i t h t h e p r o b e in o n v e r t e r o u t ( t o c o o l e r ) l i n e . P C - S e r v i c e T o o l d i s p l a y s o n l y .

1 0 . A d r i v e r i s i n t h e d r i v e r ’s p o s i t i o n .

N O T E : O b t a i n e n g i n e s p e e d d a t a f r o m t h e e n g in e m a n u f a c t u r e r o r f r o m t h e e q u i p m e n t d e a l e r o r d i s t r ib u t o r . S o m e e n g i n e m a n u f a c t u r e r s p r o v i d e a p r o g r a m m a b l e p a r a m e t e r t o lim it e n g i n e s p e e d w h e n t h e t r a n s m i s s io n o u t p u t s p e e d i s 0 r p m , s u c h a s a t a s t o p . S e t t h i s p a r a m e t e r t o a h i g h e r v a l u e t h a n t h e e x p e c t e d t r a n s m is s io n s t a l l s p e e d b e f o r e p e r f o r m in g t h e s t a l l t e s t . S ta ll te s p a ra tra n

m p e r a tu is s io n c C ® F o r p e r a tu re

O C ® F o r P C - S e r v i c e T o o l t o s t i c d a t a c o n n e c t o r o r i n s t a l l m e t e r ( d o n o t r e ly o n t h e r ) .

9 . I n s t a l l w h e e l c h o c k s .

T r a n s m i s s io n s t a l l s p e e d i s t h e m a x r p m a t ta in a b le w h e n th e e n g in e is a a n d th e to r q u e c o n v e r te r t u r b in e is n s t a lle d . A f te r a t r a n s m is s io n s t a ll t e s a c t u a l f u l l t h r o t tle e n g i n e s p e e d a t t o tu r b in e s t a ll w ith s p e c ifi c a tio n s e s t a b v e h i c l e m a n u f a c t u r e r .

b . s ta p re th e

a te n s m D O te m

n D g n o c h o e te

S u m p te m p e ra tu re : 7 1 – 9 3 º C


( 1 6 0 – 2 0 0 º F )

P R E V E N T IV E


— C o n v e r t e r o u t t e m p e r a t u r e : 8 2 – 1 0 4 º C ( 1 8 0 – 2 2 0 º F )

1 1 . A t t h e e n d o f t w o m in u t e s , r e c o r d c o n v e r t e r o u t ( t o c o o l e r ) t e m p e r a t u r e .

2 . P e r f o r m a h o t c h e c k o f t h e t r a n s m i s s io n fl u i d l e v e l a n d a d j u s t a s n e c e s s a r y

1 2 . P r o c e e d t o th e N e u tr a l C o o l D o w n C h e c k , 2 – 1 6 g . N e u t r a l C o o l D o w n C h e c k P r o c e d u r e .

3 . T u r n a l l e n g i n e a c c e s s o r ie s o f f .

d .

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4 . P la c e A l lis o n D O C F o r P C - S e r v ic e T o o l i n c lu t c h t e s t m o d e . U s e t h e s h i f t s e l e c t o r t o s e l e c t D D ( D r i v e ) . N e x t , s e l e c t 4 ( F o u r t h R a n g e ) o n t h e R a n g e P a n e l t h a t ’s d i s p la y e d o n t h e c o m p u t e r s c r e e n d u r in g C lu t c h T e s t m o d e . D o n o t t r y t o u s e t h e s h if t s e l e c t o r t o t r y t o a t t a i n 4 4 ( F o u r t h R a n g e ) . U s i n g 4 4 ( F o u r t h R a n g e ) r e d u c e s t h e t o r q u e im p o s e d o n t h e t r a n s m i s s i o n d r i v e l i n e . D o n o t p e r f o r m a t r a n s m i s s i o n s t a l l t e s t i n R R ( R e v e r s e ) . C d m r m

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6 . S lo w ly in c r e a s e e n g in e r p m s t a b i l i z e s .

u n t i l e n g i n e s p e e d

7 . R e c o r d e n g in e s p e e d . C A U T I O N : T T h e t r a n s m i s s i o n s t a l l t e s t p r o c e d u r e c a u s e s a r a p i d r i s e in t r a n s m i s s i o n fl u i d t e m p e r a t u r e t h a t c a n d a m a g e t h e t r a n s m i s s io n . N e v e r m a i n t a i n a s t a l l c o n d i t i o n o n c e e n g i n e s p e e d s t a b i l i z e s o r c o n v e r t e r o u t ( t o c o o l e r ) t e m p e r a t u r e e x c e e d s 1 5 0 ° C ( 3 0 0 ° F ) . D u r in g a s ta ll c o n d i t i o n , c o n v e r t e r o u t t e m p e r a t u r e r i s e s m u c h f a s t e r t h a n t h e in t e r n a l ( s u m p ) t e m p e r a t u r e . N e v e r u s e s u m p fl u id t e m p e r a t u r e t o d e t e r m in e t h e le n g t h o f t h e s t a l l c o n d i t i o n . I f t h e s t a l l t e s t i s r e p e a t e d , d o n o t le t t h e e n g in e o v e r h e a t .

T r a n s m i s s i o n S t a l l T e s t .

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5 . N o t if y p e r s o n n e l i n t h e a r e a t o k e e p c le a r o f t h e v e h i c l e .

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i c le is e q u ip p e o r a n e m is s io n c o n tro l p ro g r a a c c e le r a tio n , t h re c a n b e u s e d

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1 . T h e m a n u f a c t u r e r c o n c u r s w it h p e r f o r m in g a f u l l - t h r o t t l e t r a n s m i s s i o n s t a l l t e s t . 2 . T h e rp m th a n s p e e

e n g in e p r o g r a m m a b le p a r a m e t e r f o r 0 t r a n s m i s s io n o u t p u t s p e e d i s s e t h i g h e r t h e v a l u e e x p e c t e d a t t r a n s m is s io n s t a l l d .

3 . T h e v e h ic le is in a n a r e a in w h ic h t h e t r a n s m i s s i o n s t a l l t e s t c a n b e s a f e l y p e r f o r m e d . 4 . M a k e s u r e t h e f u e l c o n t r o l lin k a g e g o e s t o f u l l t h r o t t l e a n d d o e s n o t s t i c k w h e n r e l e a s e d ( i f a p p l i c a b l e ) . 5 . I n s p e c t t h e e n g i n e a i r in d u c t io n s y s t e m a n d e x h a u s t s y s t e m t o m a k e s u r e t h e r e a r e n o r e s t r i c t i o n s . 6 . P e r f o r m a c o l d c h e c k o f t h e t r a n s m i s s io n fl u i d le v e l a n d a d ju s t a s n e c e s s a r y .

8 . R e c o r d c o n v e r t e r o u t ( t o c o o le r ) t e m p e r a t u r e .

7 . C o n n e c t A l l i s o n D O C ® F o r P C - S e r v i c e T o o l t o t h e v e h i c l e d i a g n o s t ic d a t a c o n n e c t o r .

9 . R e d u c e e n g i n e s p e e d t o i d l e a n d s h if t t h e t r a n s m i s s i o n t o N N ( N e u t r a l ) .

8 . I n s t a l l a n a c c u r a t e t a c h o m e t e r ( d o n o t r e l y o n t h e v e h i c l e t a c h o m e t e r ) .

1 0 . R a is e e n g in e s p e e d t o 1 2 0 0 – 1 5 0 0 r p m f o r t w o m in u t e s t o c o o l t h e t r a n s m is s io n fl u i d .

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2 0 0 9

9 . I n s t a l l a t e m p e r a t u r e g a u g e w it h t h e p r o b e i n t h e t r a n s m i s s i o n c o n v e r t e r o u t ( t o c o o l e r )


2 - 1 7


S E R V IC E

h o s e . A l l i s o n D O C ® F o r P C - S e r v i c e T o o l d i s p l a y s s u m p t e m p e r a t u r e o n ly . f. P e r fo r m in g T e s t .

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p e e d t o 1 2 0 0 – 1 5 0 0 r p m f o r t w o l t h e t r a n s m is s io n fl u i d . A t t h e u t e s , r e c o r d c o n v e r t e r o u t ( t o a t u r e .

1 1 . P r o c e e d t o t h e N e u tr a l C o o l D o w n C h e c k 2 – 1 6 g . N e u t r a l C o o l D o w n C h e c k P r o c e d u r e .

C A U T I O N : T T h e t r a n s m i s s i o n s t a l l t e s t p r o c e d u r e c a u s e s a r a p i d r is e in t r a n s m i s s i o n fl u i d t e m p e r a t u r e t h a t c a n d a m a g e t h e t r a n s m i s s i o n . N e v e r m a i n t a i n a s t a l l c o n d i t io n o n c e e n g in e s p e e d s t a b i l i z e s o r c o n v e r t e r o u t ( t o c o o l e r ) t e m p e r a t u r e e x c e e d s 1 5 0 ° C ( 3 0 0 ° F ) . D u r i n g a s t a l l c o n d i t i o n , c o n v e r t e r o u t t e m p e r a t u r e r i s e s m u c h f a s t e r t h a n t h e i n t e r n a l ( s u m p ) t e m p e r a t u r e . N e v e r u s e s u m p fl u id t e m p e r a t u r e t o d e t e r m in e t h e l e n g t h o f t h e s t a l l c o n d i t i o n . I f t h e s t a l l t e s t i s r e p e a t e d , d o n o t l e t t h e e n g i n e o v e r h e a t . 1 . S t a r t t h e e n g i n e . W h i l e i n N N ( N e u t r a l ) a l l o w t h e t r a n s m i s s io n t o w a r m t o n o r m a l o p e r a t i n g t e m p e r a t u r e : a . S u m p te m p e ra tu re ( 1 6 0 – 2 0 0 ° F )

7 1 – 9 3 ° C

b . C o n v e r t e r o u t t e m p e r a t u r e 8 2 – 1 0 4 ° C ( 1 8 0 – 2 2 0 ° F ) 2 . P e r f o r m a h o t c h e c k o f t h e t r a n s m i s s io n fl u i d le v e l a n d a d ju s t a s n e c e s s a r y .

g .

N e u t r a l C o o l D o w n C h e c k P r o c e d u r e . 1 . A t t h e e n d o f t w o m in u t e s t h e c o n v e r t e r o u t ( t o c o o l e r ) fl u i d t e m p e r a t u r e s h o u l d r e t u r n t o w it h i n n o r m a l o p e r a t in g t e m p e r a t u r e r a n g e . 2 . If tw to tr

h .

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n o t c o o l w i t h i n b e a s tu c k i s s u e w i t h t h e t t i n g s .

T r a n s m i s s i o n S t a l l T e s t R e s u l t s . N O T E : E n v i r o n m e a s a m b ie n t te m p e e n g in e a c c e s s o r y th e p o w e r in p u t to to s u c h c o n d itio n s f r o m s p e c ifi c a tio n a c c e p t e d a s w ith in

n t a l c o n d i t i o n s , s u c h r a t u r e , a l t i t u d e , a n d l o s s v a r i a t i o n s a f f e c t t h e c o n v e r t e r . D u e , s t a l l s p e e d c a n v a r y b y ± 1 5 0 r p m a n d s t ill b e p u b l is h e d s t a l l s p e e d .

I f e n g i n e s p e e d w i t h t h e t r a n s m i s s i o n s t a l l e d i s m o r e t h a n 1 5 0 r p m b e l o w t h e s t a l l s p e e d s p e c ifi c a t io n a n e n g i n e is s u e is in d ic a t e d .

3 . T u r n a l l e n g i n e a c c e s s o r ie s o f f . 4 . W h i l e l o c a t e d i n a n i s o l a t e d a r e a , b e g i n t h e d r i v i n g t r a n s m i s s i o n s t a l l t e s t . 5 . S e le c t a h o ld u s u a l l y 2 2 ( S e R a n g e ). N e v i n R ( R e v e r s m o d e l s ) .

ra n c o n e r p e ) o

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s p e e d , h i r d t a l l t e s t n s p e e d

6 . O p e r a t e t h e e n g i n e a t 1 0 0 p e r c e n t f u l l t h r o t t le , m a x im u m g o v e r n e d s p e e d . 7 . W ith th s p e e d , s e r v ic e fu ll th r o c o m p le

e e n g in e b e g in g r a b ra k e s w t t le . W h e te s to p , r e

a t m d u a h ile n th c o r

a x im u m g o lly a p p ly in g m a in ta in in g e v e h i c le c o d th e e n g in e

v e r n e d t h e v e h i c l e 1 0 0 p e r c e n t m e s t o a s p e e d .

8 . R e c o r d c o n v e r t e r o u t ( t o c o o le r ) t e m p e r a t u r e . 9 . R e d u c e t h e e n g i n e s p e e d t o id le a n d s h if t t h e t r a n s m i s s i o n t o N N ( N e u t r a l ) . 2 - 1 8

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I f e n g i n e s ta ll s p e e d is m o r e t h a n 1 5 0 r p m a b o v e s p e c i fi c a t i o n , a t r a n s m i s s i o n i s s u e i s i n d i c a t e d . C o n d it io n s t h a t c a n c a u s e s t a l l s p e e d t o 1 5 0 r p m a b o v e s p e c i fi c a t io n c o u l d b e : – T r a n s m i s s i o n fl u i d c a v i t a t i o n o r a e r a t i o n . V e r i f y p r o p e r fl u i d le v e l u s in g t h e O il L e v e l S e n s o r ( O L S ) , i f e q u i p p e d , o r d i p s t i c k . – S l i p p i n g c l u t c h – T o r q u e c o n v e r t e r m a l f u n c t i o n – S t i c k i n g o r d a m a g e d t o r q u e c o n v e r t e r v a l v e . A l o w s t a l l s p e e d ( a t l e a s t 3 3 p e r c e n t l o w e r t h a n p u b l i s h e d s t a l l s p e e d ) c o u l d i n d i c a t e a n e n g i n e i s s u e o r a f r e e w h e e l in g s t a t o r in t h e t o r q u e c o n v e r t e r .


P R E V E N T IV E 2 – 1 7 . M o v is th e le a p ro le a a .

s t fl u u a lly n e c k m a c e d u k s .

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a k s c a n b e lo c a te d in g t h e le a k a n d r e p r y p a r ts . O n s o m e d i ffi c u lt t o lo c a t e o r a y h e lp in lo c a t in g

a n d la c in o c c a re p a a n d

1 . P o u r t h e s p e c ifi e d a m o u n t o f d y e in t o t h e t r a n s m i s s i o n fi l l t u b e .

r e p a ir e d b g o r re p a ir s io n s , a fl u i r . T h e fo l lo r e p a i r in g m

y i n g id w i n g o s t

1 . I d e n t i f y t h e fl u i d . D e t e r m in e w h e t h e r i t i s e n g i n e o i l , a u t o m a t i c t r a n s m i s s i o n fl u i d , o r h y d r a u lic fl u i d f r o m a s p e c ifi c v e h ic l e s y s t e m .

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• A t t a c h i n g b o l t s n o t c o r r e c t l y t i g h t e n e d • I m p r o p e r l y in s t a l le d o r d a m a g e d g a s k e t

c h n o r m a l o p e r a t i n g v e h i c le . A f t e r a f e w fl u i d t o i d e n t i f y t h e e le a k .

u n d t h e s u s p e c t e d a r e a . I n s p e c t a t i n g s u r f a c e s f o r l e a k s . A m i r r o r r fi n d i n g le a k s i n a r e a s t h a t a r e c h .

4 . I f t h e le a k s t i ll c a n n o t b e f o u n d , it m a y b e n e c e s s a r y t o c le a n t h e s u s p e c t e d a r e a w it h a d e g r e a s e r , s t e a m , o r s p r a y s o l v e n t . C o m p l e t e l y c le a n a n d d r y t h e a r e a . O p e r a t e t h e v e h i c le f o r s e v e r a l m ile s a t n o r m a l o p e r a t in g t e m p e r a t u r e a n d v a r y in g s p e e d s . A f t e r o p e r a t i n g , i n s p e c t t h e s u s p e c t e d l e a k a r e a . I f t h e l e a k i s n o t l o c a t e d , u s e t h e p o w d e r o r b la c k lig h t a n d d y e m e t h o d s . b .

• M o u n t in g f a c e d a m a g e d • F i l l e r p i p e o r p l u g s e a l d a m a g e d o r m i s s in g • F i l l e r p i p e b r a c k e t d i s l o c a t e d • O i l c o o l e r c o n n e c t o r fi t t i n g s l o o s e o r d a m a g e d • O u t p u t s h a f t s e a ls w o r n o r d a m a g e d • P r e s s u r e p o r t p lu g s lo o s e • C o n v e r t e r s e a l d a m a g e d • S e a l lip c u t ( c h e c k c o n v e r t e r h u b f o r d a m a g e ) • G a r t e r s p r i n g m i s s in g f r o m

s e a l

• C o n v e r t e r le a k in w e ld a r e a • D a m a g e d o r m is s in g c o n v e r t e r O - r in g s e a l • P o r o u s c a s t in g • O v e r fi lle d —

i n c o r r e c t d i p s t i c k

• P lu g g e d b r e a t h e r

P o w d e r M e t h o d .

• W a t e r o r c o o la n t i n fl u id —

1 . C le a n t h e s u s p e c te d a r e a . 2 . A p p l y a n a e r o s o l- t y p e w h it e p o w d e r , s u c h a s f o o t p o w d e r , t o t h e s u s p e c t e d a r e a .

c .

3 . D i r e c t t h e b l a c k l i g h t t o w a r d t h e s u s p e c t e d a r e a . T h e d y e d fl u id a p p e a r s a s a b r i g h t ly c o l o r e d p a t h le a d i n g t o t h e s o u r c e . d . P o s s ib l e P o i n t s o f F l u i d L e a k s a n d T h e i r C a u s e s .

F i n d i n g t h e L e a k .

2 . O p e ra te te m p e ra m in u t e s a p p r o x im

2 . O p e r a t e t h e v e h i c le u n d e r n o r m a l o p e r a t in g c o n d i t i o n s a s d i r e c t e d i n t h e k i t .

fl u id a p p e a r s m ilk y

• I n c o r r e c t e l e c t r o n i c fl u i d l e v e l i n d i c a t i o n • D r a i n - b a c k h o l e s p l u g g e d

3 . O p e r a t e t h e v e h i c le u n d e r n o r m a l o p e r a t in g c o n d i t i o n s .

• F l u i d l e v e l / p r e s s u r e i s t o o h i g h

4 . V i s u a l l y in s p e c t t h e s u s p e c t e d a r e a a n d t r a c e t h e le a k p a t h o v e r t h e w h i t e p o w d e r s u r f a c e t o t h e s o u r c e .

• Im p r o p e r ly tig h te n e d d a m a g e d t h r e a d s

B l a c k L ig h t a n d D y e M e th o d . N O a v a m a k it. th e

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b la c k le a k s c t io n s c t io n s ix .

lig . w fo

h t k R e fe h e n r th e

• P l u g g e d v e n t o r d r a i n - b a c k h o l e s f a s t e n e r s o r d i r t y /

• W a r p e d fl a n g e s o r s e a lin g s u r f a c e • S c r a t c h e s , b u r r s , o r o t h e r d a m a g e t o a s e a l i n g s u r f a c e

it i s r t o t h e u s i n g t h e c o l o r o f

• D a m a g e d o r w o r n g a s k e t • C r a c k e d o r p o r o u s c a s t in g • I m p r o p e r s e a l a n t u s e d ( w h e r e a p p l i c a b l e ) • F l u i d l e v e l / p r e s s u r e i s t o o h i g h

C o p y r ig h t ©

2 0 0 9


2 - 1 9

S E R V IC E


• P l u g g e d v e n t o r d r a i n - b a c k h o l e s • D a m a g e d s e a l b o r e • D a m a g e d o r w o r n s e a l • I m p r o p e r s e a l i n s t a l l a t i o n • C r a c k s in c o m p o n e n t • O u t p u t s h a f t s u r f a c e s c r a t c h e d , n i c k e d , o r d a m a g e d • L o o s e o r w o r n b e a r in g c a u s in g e x c e s s s e a l w e a r • I m p r o p e r d r i v e l i n e i n s t a l l a t i o n e . R lo c a t e le a k in s e a lin th e le

e p d g g a k

2 – 1 8 .

a .

a i r i n g t h e L e a k . O a n d tra c e d b a c k to c o m p o n e n ts . If a g a fl a n g e is b e n t , t h e n . T h e b e n t fl a n g e m

n c it s s k e w u s

e th e s o u rc e t is r g a s k t a ls o

le a k h e , re p e p la c e e t w ill b e re p

a s b e e n a i r t h e d , b u t t h e n o t r e p a i r a i r e d .

O U T P U T F L A N G E /Y O K E A N D O I L S E A L M A I N T E N A N C E ( A ll, E x c e p t 3 7 0 0 S P )

D i s a s s e m b l y ( F i g u r e 2 – 5 ) . 1 . I f in s t a l le d , r e m o v e e i g h t w a s h e r s ( 8 ) a n d e i g h t b o l t s ( 9 ) a n d b r a k e d r u m ( 7 ) . 2 . R e m o v e o n e b o lt ( 1 0 ) . 3 . R e m o v e fl a n g e ( 3 ) o r y o k e ( 4 ) , o n e O - r i n g ( 1 3 ) a n d r e t a i n e r p l u g ( 1 1 ) . 4 . I f p r e s e n t , r e m o v e f o u r b o l t s ( 6 ) a n d p a r k in g b r a k e a s s e m b l y ( 5 ) . 5 . I n s p e c t t h e jo u r n a l s e a lin g a r e a . M in i m u m a l lo w a b l e d i a m e t e r is 8 9 . 7 8 m m ( 3 . 5 3 5 in c h ) . I n s p e c t s l i n g e r ( 2 ) ( i f i n s t a l l e d ) a n d r e p l a c e i f n e c e s s a r y 6 . R e m o v e o u t p u t s e a l ( 1 ) u s in g P / N o r e q u i v a l e n t .

2 - 2 0

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P R E V E N T IV E


F ig u r e 2 – 5 . O u tp u t F la n g e a n d O il S e a l― b .

3 0 0 0 P r o d u c t F a m i l y ( E x c e p t 3 7 0 0 S P )

A s s e m b ly . 1 . F o r b ra J – 3 e q u re a J – 3 th e a fte in t o o u t L u b

a l l m o d e ls , e x c e p t t h o s e w it h p a r k in g k e , i n s t a l l t h e o u t p u t s e a l ( 1 ) u s i n g i n s t a l l e r 9 9 2 8 a n d J – 3 5 9 2 1 - 1 D r iv e S le e v e . I f i p p e d w i t h a p a r k i n g b r a k e , i n s t a l l t h e r s e a l u s i n g i n s t a l l e r J – 3 5 9 2 1 - 4 a n d 5 9 2 1 - 1 D r iv e S le e v e . P la c e t h e s e a l o n i n s t a l l e r t o o l s o t h e s e a l P / N f a c e s o u t w a r d r t h e s e a l i s in s t a l le d . D r iv e t h e s e a l i t s b o r e u n t i l t h e i n s t a l l e r t o o l b o t t o m s s q u a r e l y a g a i n s t i t s l o c a t i n g s u r f a c e . r i c a t e t h e s e a l .

2 . I f u s e d , i n s t a l l p a r k in g b r a k e a s s e m b l y ( 5 ) a n d r e t a i n w i t h f o u r b o l t s ( 6 ) . T i g h t e n b o l t s t o 2 2 8 – 2 6 6 N ∙ m ( 1 6 8 – 1 9 6 lb f t ) .

7 . I n s t a l l r e t a i n e r p l u g ( 1 1 ) i n t o t h e y o k e ( 4 ) o r fl a n g e ( 3 ) . T i g h t e n b o l t ( 1 0 ) t o 7 0 – 8 0 N ∙ m ( 5 2 – 5 9 l b f t ) . 8 . I n s t a l l b r a k e d r u m ( 7 ) a n d e i g h t b o l t s ( 9 ) a n d e i g h t w a s h e r s ( 8 ) . T i g h t e n b o l t s ( 9 ) t o 5 6 – 6 6 N ∙ m ( 4 1 – 4 9 lb f t ) .

2 – 1 9 .

a .

Y O K E A N D O IL S E A L M A I N T E N A N C E ( 3 7 0 0 S P )

D i s a s s e m b l y ( F i g u r e 2 – 6 ) . 1 . H o ld y o k e ( 5 ) o r ( 3 ) a n d r e m o v e o u t p u t n u t s ( 1 ) a n d fl a t w a s h e r s ( 2 ) .

3 . I n s t a l l fl a n g e ( 3 ) o r y o k e ( 4 ) .

2 . R e m o v e y o k e ( 5 ) a n d ( 3 ) b y u s in g a s lid e h a m m e r o r a s im ila r t o o l .

4 . I n s t a l l O - r in g ( 1 3 ) o n r e t a i n e r p l u g ( 1 1 ) . L u b r i c a t e t h e O - r i n g .

3 . R e m o v e o il s e a ls ( 4 ) u s in g P / N J – 2 4 1 7 1 - A .

5 . I n s e r t b o l t ( 1 0 ) t h r o u g h r e t a i n e r p l u g ( 1 1 ) .

4 . I n s p e c t t h e f r o n t a n d r e a r o u t p u t y o k e s a n d t h e f r o n t a n d r e a r o il s e a l s f o r w e a r a n d d a m a g e .

6 . I n s t a l l a n e w O - r in g ( 1 2 ) o v e r b o l t ( 1 0 ) s o t h e O - r i n g s e a t s a g a i n s t t h e r e t a i n e r p l u g ( 1 1 ) .

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4 – 2 c . R e m o v a l o f S p e e d S e n s o r s

I n t e g r a l O il C o o le r

4 – 2 d . R e m o v a l o f In te g ra l O i l C o o l e r ( F o l d o u t 1 8 - 1 )

I n t e g r a l R e t a r d e r S u m p O i l C o o l e r

4 – 2 e . R e m o v in g I n t e g r a l R e t a r d e r S u m p O il C o o le r ( F o l d o u t 1 8 - 2 )

P T O (s )

4 – 2 f. R e m o v a l o f P T O (s ) ( F o l d o u t 1 9 - 2 )

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3 7 0 0 S P

A s s e m b l y ( F i g u r e 2 – 6 ) . 1 . In s p e c t f ro n t o u tp u t y o k e y o k e (5 ) fo r w e a r o n th e N o s c o r in g is p e r m it te d r e m o v e d b y u s in g a s o ft M in im u m a llo w a b le s e a l 7 6 . 2 0 m m ( 3 . 0 0 0 in c h ) .

(3 ) a n d re a o u tp u t s e a l a n d s h o u ld s to n e o r c ro jo u r n a l d ia m

2 . In s ta ll o il s e a ls ( 4 ) u s in g P /N P / N J – 3 5 9 2 1 - 1 .

r o u t p u t jo u r n a l . b e c u s c lo t h . e t e r i s

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3 . I n s t a l l r e a r o u t p u t y o k e ( 5 ) a n d f r o n t o u t p u t y o k e ( 3 ) b y u s in g a s li d e h a m m e r o r a s im i l a r t o o l . 4 . A p p l y s e a la n t o n b o t h s id e s o f fl a t w a s h e r s ( 2 ) a n d in s t a l l t h e fl a t w a s h e r s ( 2 ) . 5 . I n s t a l l o u t p u t n u t s ( 1 ) a n d t t i g h t e n t h e n n u t s t o 6 1 0 – 8 1 5 N ∙ m ( 4 5 0 – 6 0 0 lb f t ) .

2 – 2 0 .

O N - V E H IC L E M A IN T E N A N C E

T h e f o l l o w i n g m a y b e s e r v ic e d o r r e m o v e d w i t h t h e t r a n s m is s io n m o u n t e d i n t h e v e h i c le . R e f e r t o t h e i n d i c a t e d p a r a g r a p h f o r r e m o v a l i n s t r u c t i o n s Ite m Y o k e M a in t e n a n c e

2 - 2 2

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8 . E /Y M A c e p F ig u

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4 – 2 g . R e m o v a l o f T r a n s f e r C a s e M o d u l e — 3 7 0 0 S P ( 1 ) 4 – 2 h . R e m o v a l o f C o n tr o l V a lv e M o d u l e ( F ig u r e 4 – 6 )

S E C T IO N 3 – 1 .

3 —

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T h i s s e c t i o n p r o v i d e s g e n e r a l i n f o r m a t i o n f o r t r a n s m i s s i o n o v e r h a u l . T h e i n f o r m a t i o n p r o v i d e d i n c l u d e s : • T o o l s a n d e q u i p m e n t r e q u ir e d f o r o v e r h a u l • R e p la c e m e n t p a r t s in f o r m a t io n • C l e a n l i n e s s a n d c a r e f u l h a n d l i n g • C l e a n i n g a n d i n s p e c t i o n • A s s e m b ly p r o c e d u r e s • T r a n s m i s s i o n r e m o v a l a n d i n s t a l l a t i o n • L o c a t in g w e a r d a t a • L o c a t i n g s p r i n g s p e c i fi c a t i o n s • L o c a t i n g t o r q u e s p e c i fi c a t i o n s f o r p l u g s , b o l t s , a n d n u t s

3 – 2 .

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a . I m p r o v i s e d T o o l s a n d E q u i p m e n t . T h e f o l lo w in g it e m s m a y b e im p r o v i s e d . • W o r k T a b le — 5 0 0 k g ( 1 0 0 0 lb ) c a p a c it y ( F i g u r e 3 – 1 ) • O v e rh a u l S ta n d — ( F i g u r e 3 – 2 )

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b . S p e c i a l T o o l s . S p e c i a l t o o l s a r e i l l u s t r a t e d in F i g u r e 3 – 3 . T h e y a r e id e n t ifi e d in T a b le 3 – 1 , f o l l o w i n g t h e s p e c i a l t o o l i l l u s t r a t i o n s . c . M e c h a n i c ’ s T o o l s a n d S h o p E q u i p m e n t . T T h e f o l l o w i n g t o o l s , i n a d d i t i o n t o t h e c o m m o n t o o l s o r d i n a r i l y r e q u i r e d , s h o u l d b e a v a i l a b l e . • C o m m o n h a n d t o o ls , m e t r ic w h e r e r e q u ir e d • M e t r ic w r e n c h s e t ( s o c k e t s , b o x - e n d w r e n c h e s , a n d A lle n w r e n c h e s ) • R e t a i n i n g r i n g p l i e r s • M i c r o m e t e r ( m e t r i c p r e f e r r e d ) • D e p t h m i c r o m e t e r ( m e t r i c p r e f e r r e d ) • D i a l i n d i c a t o r s e t ( m e t r i c p r e f e r r e d ) • M e t r ic h e a d l e s s g u i d e b o l t s s e t • M 1 0 e y e b o lt • M 1 6 e y e b o lt • S u ita b le h o is t—

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A U ill d n ly a rts

T I O N : C a u s t i c c l e a n i n g c o m p o u n d s a m a g e s o m e t r a n s m i s s io n p a r t s . U s e m i n e r a l s p i r i t s t o c l e a n t r a n s m i s s i o n .

W A R N I N G : U s e a p p r o p r i a t e s a f e t y e q u i p m e n t s u c h a s s a f e t y g l a s s e s , s a f e t y s h o e s , a n d g l o v e s .

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5 – 7 a , b ; 5 – 1 2 e , f , n , o , v ; 5 – 1 3 c , d ; 5 – 1 4 a , b

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b l e f r o m o t h e r m a n u f a c t u r e r s . A l l i s o n n y r e s p o n s i b i l i t y f o r t h e p r o d u c t s o r t o o l s e s . 4 8 0 9 2


G E N E R A L 3 – 3 . a . th e P C ( w w in f o th e

O V E R H A U L

R E P L A C E M E N T P A R T S

O r d e r in g In la t e s t v e r s io 2 1 5 0 E N , o r A w .a llis o n t r a n r m a t io n . D o re fe re n c e n u

fo r m n o f llis o s m is n o t o m b e

a t i o n . P a r ts C n T ra n s m s io n .c o m rd e r re p r s in th is

R e f e r t o a t a l o g i s s io n E x t r a n e / e x t r a n e t ) , f o r la c e m e n t p a r ts s e r v ic e m a n u a

t p a r t s u s i n g l .

IN F O R M A T IO N

3 – 5 .

C L E A N IN G

A N D

a c o a p

a u s e s M e r m it e ff e m a t e r ia l . E v e n m h a s v a lv

c t in s te r p a m

. le r s a

b . b . P a r t s N o r m a l l y R e p l a c e d a t O v e r h a u l . T h e f o l l o w i n g p a r t s a r e n o r m a l l y r e p l a c e d a t e a c h t r a n s m i s s i o n o v e r h a u l :

• O - r in g s • B u s h in g s

i o n . A l l p a r t s p e c t io n . D o n t h e tr a n s m is s r t ic le s c a n c a u a l f u n c t io n .

m u o t a io n s e

s t llo d u c lo

b e w d i r t r i n g s e - fi t

C l e a n in g P a r t s . m is s io n p a r t s , e x c e d c lu tc h p la te s v o la t ile m in e r a l s a s o lu t io n f o r s te - fa c e d c lu t c h p la r a l s p i r i t s o n l y .

c e p t , b y p i r i t s . a m t e s

2 . D r y a l l p a r t s , e x c e p t b e a r i n g a s s e m b l i e s , w i t h c o m p r e s s e d a i r . T o p r e v e n t r u s t , l u b r i c a t e s t e a m - c le a n e d p a r t s a s s o o n a s t h e y a r e d r y .

• I n p u t a n d o u t p u t s h a f t s e a l s • T h r u s t w a s h e r s

3 . C le a n fl u id p a s s a s o ft w ir e t h r o u g h th e m w ith m in e r a w ith c o m p r e s s e d

• R e t a in in g r in g s d a m a g e d b y r e m o v a l o r a b n o r m a l w e a r • S p i r a l r e t a i n i n g r i n g ( 4 ) ( F o l d o u t 8 - 1 ) • P i s t o n s e a l r i n g s

g e s b y w o r k in g a p i e c e o f t h e p a s s a g e s a n d fl u s h in g l s p i r i t s . D r y t h e p a s s a g e s a i r .

4 . E x a m in e p a r t s , e s p e c ia l ly fl u i d p a s s a g e s , a f t e r c l e a n i n g t o m a k e c e r t a i n t h e y a r e e n t i r e l y c l e a n . R e - c l e a n p a r t s if n e c e s s a r y .

• O i l fi l t e r s • S u c t i o n fi l t e r ( 2 ) ( F o l d o u t 1 5 - 1 ) • C lu t c h p a c k s , a s r e q u i r e d

c .

W A R N I N G : D o n o t b u r n d i s c a r d e d T e fl o n s e a l s ; t o x i c g a s e s a r e p r o d u c e d b y b u r n i n g T e fl o n ® .

2 . S o a k p a r t i c u l a r l y d i r t y b e a r i n g s o r o n e s fi l l e d w i t h h a r d e n e d g r e a s e i n m i n e r a l s p i r i t s b e f o r e t r y in g t o c le a n t h e m .

C A R E F U L H A N D L IN G

H a n d l e p a r t s a n d s u b a s s e m b l ie s c a r e f u l l y t o p r e v e n t n i c k i n g , s c r a t c h i n g , a n d d e n t i n g . P a r t s t h a t fi t c l o s e l y t o g e t h e r a n d h a v e a s p e c i fi c o p e r a t i n g c le a r a n c e c a n b i n d if d a m a g e d . P a r t s t h a t d e p e n d u p o n s m o o t h s u r f a c e s f o r s e a lin g m a y l e a k if s c r a t c h e d . C o n t r o l v a l v e b o d y a s s e m b l y p a r t s a r e e s p e c i a l l y s u s c e p t i b l e t o l e a k i n g i f s c r a t c h e d . V a l v e s , w h e n d r y , m u s t m o v e f r e e l y b y t h e i r o w n w e i g h t . H a n d l e t h e s e p a r t s c a r e f u l l y a n d p r o t e c t t h e m d u r i n g r e m o v a l , c l e a n i n g , i n s p e c t i o n , a n d i n s t a l l a t i o n . K e e p c o n t r o l v a l v e b o d y a s s e m b l y p a r t s i n c l e a n c o n t a i n e r s u n t i l i n s t a l l a t i o n .

2 0 0 9

C l e a n in g B e a r i n g s . 1 . B e a r in g s t h a t h a v e b e e n in s e r v ic e s h o u ld b e t h o r o u g h l y c l e a n e d i n v o l a t i l e m i n e r a l s p i r i t s .

®

C o p y r ig h t ©

a lf u n c t iv e to e n in u t e e s , to

1 . C le a n a l l m e t a l lic t r a n s b e a r in g s a n d f r ic t io n - fa s t e a m - c le a n in g o r w ith D o n o t u s e c a u s tic s o d c le a n in g . C le a n f r ic t io n a n d b e a r in g s w ith m in e

• G a s k e t s

3 – 4 .

D ir t C a n to p fo r e ig n s e m b ly rts , s u c

IN S P E C T IO N

W A R N I N G : N e v e r d r y b e a r i n g th e m w it h c o m p r e s s e d a ir. A b e a r in g c a n d is in t e g r a te , a llo w r o l le r s to b e c o m e le th a l fl y in g A l s o , s p i n n i n g a b e a r i n g w i t h o c a n d a m a g e t h e b e a r in g .

s b y s p in n in g b p r o je u t lu b

s p i n n i n g i n g a l l s o r c t i l e s . r i c a t i o n

3 . B e f o r e i n s p e c t i o n , l u b r i c a t e t h e b e a r i n g s w i t h t r a n s m i s s i o n fl u i d . d . K e e p fa ilu r e s a b e a r in g . in s t a lla tio m a x im u m

in re K e n . b

g B u s u e p O b e a r

e a r in g s C le a lly c a u s e d b e a r in g s c le s e rv e th e fo in g lif e :


a n b y a n llo w

. B B a l l o r r o l l e r d ir t o r g r it in d u r in g r e m o v in g r u le s to p

b e a r i n g t h e a l a n d r o v i d e

3 - 7

S E R V IC E

• D o n o t u n w ra p n e w b e i n s t a l l e d .

M A N U A L — 3 0 0 0 P r o d u c t F a m i l y — A l l i s o n 4 t h G e n e r a t i o n C o n t r o ls — V O C A T IO N A L M O D E L S b e a r in g s u n t il th e y a r e t o

• D o n o t r e m o v e t h e g r e a s e in w h ic h n e w b e a r in g s a r e p a c k e d u n t il t h e y a r e t o b e i n s t a l l e d . • D o n o t l a y b e a r in g s o n a d ir t y b e n c h . P la c e b e a r i n g s o n c l e a n , l i n t - f r e e p a p e r . • I f a b e a r i n g i s n o t i n s t a l l e d i m m e d i a t e l y , w r a p o r c o v e r t h e l u b r i c a t e d b e a r i n g w i t h c l e a n p a p e r o r lin t - f r e e c l o t h t o k e e p o u t d u s t . e .

In s p e c tin g

B e a r i n g s .

1 . I n s p e c t b e a r i n g s f o r r o u g h r o t a t i o n . R e p l a c e a b e a r i n g i f i t s r o t a t i o n i s s t i l l r o u g h a f t e r c l e a n i n g a n d l u b r i c a t i o n . 2 . In s p c ra c r o lle d e fe

e c t k e d r o r c ts

b e a r in , o r c h b a ll w a r e fo

g s f o r s c o r e d , p i t t e d , s c r a t c h e d , i p p e d r a c e s , a n d f o r e x c e s s i v e e a r . R e p l a c e t h e b e a r i n g i f a n y u n d .

3 . I n s p e c t a d e f e c t iv e b e a r in g ’s b s h a ft fo r g ro o v e d , b u rre d , o r g th a t in d ic a t e t h e b e a r in g h a s b th e b o r e o r o n th e s h a ft. If th e b e r e p a ir e d w ith c r o c u s c lo t h , d e f e c t i v e p a r t .

o re a n d a lle d c o n e e n tu r n d a m a g e r e p la c e

m a t i n g d i t i o n s i n g i n c a n n o t t h e

4 . W h e n r e m o v in g a b e a r in g , d o n o t a p p ly p r e s s u r e a c r o s s t h e b a l ls . T h i s c a n c a u s e b r i n e l l i n g a n d b e a r i n g f a i l u r e . 5 . If a b e a r in g m u s t b e r e m w ith o u t th e p r o p e r to o l, p w h i c h is a d ja c e n t t o t h e If a p r e s s is n o t a v a i la b le b e a r in g w ith a d r if t a n d h

o v re s m o , c a m

N O T E : W h e n i n s t a l l i n g t h o n to a p ilo t o r b o r e , t a k e t h a t t h e fi lle t o n e it h e r t h e o f th e b e a r in g m a t e s w ith th e r e s p e c t iv e p ilo t o r b o r F a ilu r e t o d o s o w ill r e s u lt a n d tr a n s m is s io n d a m a g e

3 - 8

e d o r in s ta s o n ly o n u n t in g s u r a r e f u l ly s e m e r . r u s t b e a r in c a re to e n ID o r th e t h e fi lle t o e ( F ig u r e 3 in b e a r in g .

lle th e fa c a t

d r a c e e . t h e

g s s u r e O D f – 4 ) . f a i l u r e

C o p y r ig h t ©

F ig u r e 3 – 4 . T h r u s t B e a r in g f. In s p e c tin g S u r f a c e s .

C a s t P a r t s a n d M a c h i n e d

1 . In s p a n d c ro c th a t

e c t b o re d ir t. R e u s c lo t h a re d e e

2 . In s p If a n c o m a n d o u t

e c t a ll fl u id p a s s a g e s o b s tr u c t io n is f o u n d p r e s s e d a ir, o r b y w o fo r th th r o u g h th e p a s w i t h m i n e r a l s p i r i t s .

3 . In s p e c t s c ra tc h e d e fe c ts C le a n th th e d e fe

O r i e n t a t i o n

s fo r w e a r, s c ra tc m o v e s c ra tc h e s a . C le a n th e p a r t. p ly s c r a t c h e d o r g fo r o , re m r k in g s a g e

m o u n t in g fa c e s fo s , a n d fo r e ig n m a w it h c r o c u s c lo t h e p a rt. If s c r a tc h e c t i v e p a r t .

h e s , g n d b u R e p la ro o v e b s tr o v e a s o a n d

r n ic k tte r. R o r a s s a re

r o o v e s , r r s w it h c e p a r t s d .

u c it ft fl

t io n s . w i t h w ir e b a c k u s h in g it

s , b u r r s , e m o v e a n y o f t s t o n e . d e e p , r e p l a c e

4 . I n s p e c t t h r e a d e d o p e n i n g s f o r d a m a g e d t h r e a d s . C le a n d a m a g e d t h r e a d s w it h t h e c o r r e c t s i z e t a p . C A U T I O N : S o m e p a r t s h a v e S p i r a l o c k ® t h r e a d e d h o l e s . A r e p a i r a b l e t h r e a d e d h o l e c a n o n l y b e r e p a i r e d u s i n g a S p i r a l o c k ® t a p . A s t a n d a r d t a p w i ll e l i m i n a t e t h e l o c k i n g f e a t u r e a n d r e q u i r e t h a t t h e p a r t b e r e p l a c e d . S p i r a l o c k ® t a p s a r e a v a i l a b l e f r o m : S p i r a l o c k ® C o r p o r a t i o n , M a d i s o n T e c h C e n t e r , 2 5 2 3 5 D e Q u in d r e , P O B o x 7 1 6 2 9 , M a d i s o n H e i g h t s , M I , 4 8 0 7 1 - 0 6 2 9 ; P h o n e : ( 8 0 0 ) 5 2 1 - 2 6 8 8 .


G E N E R A L

O V E R H A U L

A s o f t h i s p r i n t i n g , t h e f o l l o w i n g p a r t s h a v e S p i r a l o c k ® t h r e a d e d h o l e s :

e d g e s in p is to n g r o o v e s o r o n a m a t in g s u r f a c e t h a t c o u ld d a m a g e a n e w s e a l.

• T o r q u e c o n v e r t e r c o v e r — fl e x p la t e a d a p t e r b o l t h o l e s a n d l o c k u p c l u t c h b a c k p l a t e b o l t h o l e s .

2 . R e p l a c e a l l c o m p o s it io n g a s k e t s . 3 . I n s p e c t h o o k - t y p e s e a l r i n g s f o r w e a r , b r o k e n h o o k s , a n d d i s t o r t i o n .

• O u t p u t s h a f t w i t h s i n g l e - b o l t fl a n g e r e t e n t i o n . 5 . In s p e c t t h e r ib r e a c tio n p la t e r ib s . R e p la c e b e y o n d w e a r T a b le 7 – 1 in S

s in s id w e a r g h o u s in lim its . e c tio n

e th e m ro o v e s g s th a t (R e fe r 7 )

a in h o in t h e h a v e s to W e a

u s in s id e p lin e r L im

4 . I n s t a l l a n e w h o o k - t y p e s e a l r i n g i f t h e o l d r i n g s h o w s a n y w e a r o n it s o u t s id e d i a m e t e r , o r i f t h e r e is e x c e s s i v e s id e w e a r .

g f o r o f t h e s w o r n it s ,

5 . M e a s u re s e s e a lr in g in t o a fe e le r g a u s e a lr in g s h a to S e c t io n 7 D A T A . )

6 . R e p l a c e h o u s in g s o r o t h e r c a s t p a r t s t h a t a r e c r a c k e d . 7 . I n s p e c t a l l m a c h i n e d s u r f a c e s f o r d a m a g e t h a t c o u ld c a u s e fl u i d le a k a g e o r o t h e r m a l f u n c t io n . R e w o r k o r r e p la c e d e f e c t iv e p a r t s . 8 . In s p e c t m o d u le b ro k e n im p e r fe s e v e re f a i l u r e . g .

th e a n d la n d c t io n fl u id

o il tra m a in s , c ra s . T h le a k a

c k h c k e s g e

s o f th e c o o u s in g f o r s , d irt, a n d e im p e r f e c le a d in g to

n tro l p o ro la n d t io n s tra n

2 . R d p n

v a l v e s it y , s u r f a c e w i l l c a u s e s m i s s i o n

fo n c s a c a s s

r s c o re e o f o v c lo t h . R s c ra p e r e fu lly .

s , b e rh e e m r o r in s p

u r rs , a t in g o v e b k n if e e c t b

s h a r p . R e m o v e u r r s a n d b la d e . u s h i n g s

a lr in g e n d g a p its r e s p e c tiv e g e to m e a s u re v in g e x c e s s iv e . W E A R L IM I T

c t c lu t c h , b u rrs , d in t e r fe r e is to n s e a s , b u rrs , s c lo t h . th e h o u s

7 . In s p e c t p is to n b u rrs , d e n ts , d a m a g e th e s e d g e s , b u rrs , c r o c u s c lo t h . fr o m th e p is to i.

h o u s in e n ts , o w ith m l. R e m o r n ic k T h o ro u in g b e f

g s e a r d is p a t in g o v e ra s w ith g h ly c o re a s

b y in s e s e a l in g e n d g a e n d g a S A N D

r tin b o p . p . S P

g t h e r e . U s e D is c a r d ( R e f e r R I N G

l i n g s u r f a c e s f o r l a c e d m e t a l t h a t p a r t s o r d a m a g e i s e d m e t a l , s h a r p a s o f t s t o n e a n d l e a n a l l r e s i d u e s e m b l y .

s e a lr in g g r o o v e s f o r n o r d is p la c e d m e ta l th a t e a l. R e m o v e r a is e d m e o r n ic k s w ith a s o ft s t o T h o r o u g h ly c le a n a ll r e n b e f o r e a s s e m b l y .

i c k s , c o u l d t a l , s h a r p n e a n d s i d u e

I n s p e c t i n g G e a r s . 1 . I n s p e c t g e a r s f o r s c u f f e d , n i c k e d , b u r r e d , o r b r o k e n t e e t h . I f a d e f e c t c a n n o t b e r e m o v e d w it h a s o f t s t o n e , r e p l a c e t h e g e a r .

C A U T I O N : W h e n r e m o v i n g a d e f e c t i v e b u s h in g d o n o t d a m a g e t h e b u s h in g b o r e .

2 . I n s p e c t g e a r t e e t h f o r w e a r t h a t h a s c h a n g e d t h e o r i g i n a l t o o t h s h a p e . I f t h i s c o n d i t i o n i s f o u n d , r e p la c e t h e g e a r .

e p la c e e p ly a r ts m o t d a m

3 . In s p e c t th e s c ra tc h e s , w ith a s o f t c a n n o t b e t h e g e a r .

e b u s h in s c o re d , a te d to a g e d o

g s o r b u r w

th a e x c s h in o rn

t a re e s s iv g s to b e y o

o u e ly b e n d

t o f - r o u n d , w o r n . I n s p e c t s u r e t h e y a r e u s e .

3 . I n s p e c t t h r u s t w a s h e r s f o r d i s t o r t i o n , s c o r e s , b u r r s , a n d w e a r . R e p l a c e a t h r u s t w a s h e r if d e f e c t iv e o r w o r n . h .

6 . In s p e n ic k s c o u ld th e p e d g e c ro c u fro m

I n s p e c t i n g B u s h i n g s a n d T h r u s t W a s h e r s . 1 . I n s p e c t b u s h in g s e d g e s , a n d e v id e s c o r e s w it h c r o c u s h a r p e d g e s w it h B e fo r e in s t a llin g , f o r s ig n s o f d is t r e

IN F O R M A T IO N

I n s p e c t i n g S e a lr i n g s a n d G a s k e t s . 1 . I n s p e c t p i s t o n s e a l r i n g s a n d l i p - t y p e s e a l s f o r n i c k s , c u t s , t e a r s , s p l i t s , a n d p a t t e r n d a m a g e . A d a m a g e d s e a l c a n i n d i c a t e r o u g h o r s h a r p

C o p y r ig h t ©

2 0 0 9

4 . In s p e c d is tre s a g e a r R e u s in c u s to m B a c k la g e a r w n a tu r e

th r u s a n d b b s to n e re m o v

t fa c e o f g u r r s . R e m . I f s c r a t c e d w ith a

e a r s fo o v e s u h e s a n s o ft s to

r s c o r e s , c h d e fe c t s d s c o r e s n e , r e p l a c e

t g e a r s f o r lo a d p a t t e r n a n d s ig n s o f s . A n y s i g n o f d i s t r e s s i n d i c a t e s t h a t f a i lu r e d u r in g o p e r a t io n i s p o s s i b l e . g d i s t r e s s e d g e a r s is a n i n d i v id u a l e r d e c i s io n b a s e d o n e x p e r ie n c e . s h c a n n o t b e u s e d t o e s t a b l is h c r i t ic a l e a r . B a c k la s h t o l e r a n c e s a r e o f s u c h t h a t a g e a r u s u a l l y p i t s , s c u f f s , s c o r e s ,


3 - 9


S E R V IC E

o r g a lls lo n g b e f o r e g e a r w e a r b e c o m e s c r i t i c a l . j .

b u r r s a n d m i n o r s u r f a c e i r r e g u l a r i t i e s u s i n g a s o f t s t o n e . R e p l a c e p la t e s w h ic h h a v e a n y d e f e c t s .

I n s p e c t i n g S p l i n e d P a r t s . 1 . In s p e c t s c h ip p e d , a s o ft s to a r e fo u n d h a rm fu l e s p lin e d p 2 . S g w e 7 s W m

p lin e a u g e o rn a x c e s s . W E p lin e E A R a x im

p l in e d p a r t s o r b u rre d s p n e . R e p la c e . S p lin e w e x c e p t w h e re a r t s .

w e a th ic re a iv e A R w e a L IM u m

f o r s tr ip p e d lin e s . R e m o th e p a rt if o a r is n o t c o it a f fe c t s t h

3 . T b d ( c A

, t w i s t e d , v e b u r r s w i t h t h e r d e f e c t s n s id e r e d e fi t o f t h e

h e a m o u n t y m e a s u r in ia m e te r o f F ig u r e 3 – 5 ) o n e . ( R e fe N D S P R IN

o f c lu t c h p la t e c o n e is d g th e d is ta n c e b e t w e e n th e p la t e a n d a le v e l s u . D is c a r d p l a t e s h a v in g r t o S e c t io n 7 . W E A R L G D A T A ) .

4 . D e t e r m in e o il g m ic ro m e t e r o r s u r fa c e (to ta l) m e a s u r in g t h e th e p la te a t th e th is m e a s u r e m R e p la c e p la te s g ro o v e d e p th . L I M I T S A N D S

r is d e t e r m in e d b y c o m p a r in g f e e l e r k n e s s w i t h t h e t h i c k n e s s o f t h e o n t h e s p li n e . R e p l a c e p a r t s h a v i n g s p l in e w e a r . ( R e f e r t o S e c t io n L IM IT S A N D S P R I N G D A T A ) . If r l i m i t s a r e n o t s p e c i fi e d i n 3 – 8 . I T S , th e n u s e 0 . 3 8 m m ( 0 . 0 1 5 in c h ) w e a r a s t h e s p e c ifi c a t io n .

r o o v e d e p t h w ith b y m e a s u rin g th e th ic k n e s s o f th e p th ic k n e s s o f th e s o il g ro o v e , a n d s e n t fro m th e to ta l n o t h a v in g t h e m ( R e fe r t o S e c tio n P R IN G D A T A ) .

e t e r m in e d t h e i n s id e r f a c e e x c e s s i v e I M I T S

a d e p t h s m o o t h l a t e , t e e l p a r t o f u b t r a c t i n g t h i c k n e s s . in im u m o il 7 . W E A R

3 . B a c k l a s h c a n n o t b e u s e d t o e s t a b lis h c r it ic a l s p l in e w e a r . A c c u r a t e b a c k la s h m e a s u r e m e n t r e q u i r e s t h e m a t i n g p a r t s t o b e c o n c e n t r i c a l l y l o c a t e d . k . I n s p e c t i n g T h r e a d e d P a r t s . I I n s p e c t t h r e a d e d p a r t s f o r b u r r e d o r d a m a g e d t h r e a d s . R e m o v e b u r r s w it h a s o f t s to n e o r fi n e fi le . R e p l a c e d a m a g e d p a r t s . l. re ta w e a fo u n g ro o m o r o

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e c t s p r in g t, o r w e a r c e th e s p r . (R e fe r to

s f o r s i g n s d u e t o i n g i f a n y T a b l e 7 – 2 . )

I n s p e c t i n g C l u t c h P l a t e s ( F i g u r e 3 – 5 ) . 1 . In s p e c t fr ic s p lin e d p la p a r t ic le s , s e x c e s s iv e s h a llo w o il te e th . R e m s to n e . R e p

t io n - fa c e d c lu te s ) fo r b u r rs e v e r e ly p itt e d w e a r, c o n e , c g ro o v e d e p th o v e b u rrs u s la c e p la t e s w

2 . In s p e c t s te fo r b u rrs , s c o n e , d is t o c ra c k s , b re

e l p la te c o r in g , r tio n , im a k s , o r

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t c h p l a t e s ( i n t e r n a l l y , e m b e d d e d m e t a l f a c e s , l o o s e f a c e s , r a c k s , d i s t o r t i o n , , o r d a m a g e d s p l i n e in g a s o f t h o n i n g h i c h h a v e a n y d e f e c t s .

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F ig u r e 3 – 5 . M e th o d o f M e a s u r in g P l a t e C o n e

C l u t c h

o . I n s p e c t i n g S w a g e d a n d I n t e r f e r e n c e - F i t P a r t s . I f t h e r e i s e v i d e n c e o f l o o s e n e s s , t h e a s s e m b ly s h o u l d b e r e p l a c e d . p . In R e ta r fo r fre t h e b a s e a t i n q .

s p e d e r e m l l s . g d

c t in g R e ta in e r a n d S t a t o r . I I n s p e c t b a l l s o v e m e n t. In s p e c t th e A n y r e s t r ic t io n c o u l d u r in g r e ta r d e r a p p lic a

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1 . I n s p e c t s u r f a c e s in c o n t a c t w it h h o o k - t y p e , s c a r f - c u t , a n d b u t t - jo i n t s e a l r i n g s f o r s t e p w e a r , n i c k s , s c r a t c h e s , a n d s c o r i n g . U s e a s o f t s t o n e o r c r o c u s c lo t h t o r e m o v e o n l y t h e r a i s e d m e t a l p o r t i o n o f t h e s e d e f e c t s . P o l i s h i n g t h e a r e a t o r e m o v e a d e f e c t i s n e i t h e r n e c e s s a r y n o r d e s i r a b l e . I f t h e d e f e c t s a r e t o o s e v e r e t o c o r r e c t , r e p l a c e t h e d e f e c t i v e p a r t .


G E N E R A L 2 . In s p e c t s u r fa c lip - t y p e s e a ls o r o th e r s u rfa e m b e d d e d p a fl a n g e s o r o th e x te rn a l c o n ta a n d re s to r e th s c o re s o r s c ra

O V E R H A U L

e s i n c o n t a c t w i t h s p r i n g - l o a d e d , f o r n i c k s , s c r a t c h e s , r o u g h n e s s , c e i r r e g u l a r i t i e s . I n s p e c t f o r r t i c l e s , s t e p - w e a r , a n d d i r t o n e r c o m p o n e n t s e x p o s e d t o m in a t i o n . R e m o v e t h e d e f e c t s e fi n is h . R e p l a c e t h e p a r t if t c h e s p e r m it fl u i d le a k a g e .

N O T E : B e g i n n i n g J a n u a r y 2 0 0 6 a n d w i t h S / N 6 5 1 0 6 3 0 0 8 9 a n d S / N 6 5 2 0 0 5 7 8 2 0 , a ll s p e e d s e n s o r s w e r e r e d e s ig n e d . S e e F i g u r e 3 – 7 t o i d e n t i f y f o r m e r o r c u r r e n t s p e e d s e n s o r t y p e s . S e e T a b le 3 – 2 f o r a l l s p e e d s e n s o r s p e c i fi c a t i o n s o f f o r m e r a n d c u r r e n t t y p e . S e e T S 3 9 8 9 f o r D T C , c o n n e c t o r , a n d c i r c u i t i n f o r m a t i o n . I n f o r m a t io n a b o u t t h i s c h a n g e m a y a l s o b e f o u n d in S I L 5 - W T - 0 6 . r.

IN F O R M A T IO N

F ig u re 3 – 6 . S p e e d

S e n s o r O r i e n t a t i o n

I n s p e c t i n g E l e c t r i c a l C o m p o n e n t s . 1 . P e r f o r m t h e f o l lo w in g s t e p s f o r t h e i n p u t , t u r b i n e , a n d o u t p u t s p e e d s e n s o r s . • R e p la c e s p e e d s e n s o r if t h e s p e e d s e n s o r s h o w s s ig n s o f c r a c k in g a n d / o r o i l l e a k a g e . • R e p la c e t h e s p e e d s e n s o r if t h e a t t a c h m e n t b r a c k e t i s b e n t o r d a m a g e d o r t h e s p e e d s e n s o r is lo o s e in it s b o r e . • M a k e s u r e t h e s p e e d s e n s o r c o n n e c tio n is o r ie n t e d a s s h o w n in F i g u r e 3 – 6 . • M e s e n th e s p e

a s s o fo e d

u re th e r. If th e l lo w in g s e n s o

r e s is t a n c e o f t h e s p e e d r e s is t a n c e d o e s n o t m e e t s p e c i fi c a t i o n s , r e p l a c e t h e r .

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2 0 0 9


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2 . M a d F s

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e a s u re th n d P C S 1 o e s n o t m ig u re 3 – 8 o l e n o i d .

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F ig u r e 3 – 8 . M a in M o d , T C C , a n d P C S 1 t h r o u g h P C S 6 —

S o l e n o i d R e s i s t a n c e v s . T e m p e r a t u r e

T a b l e 3 – 3 . S u m p S o l e n o i d R e s is t a n c e S u m p (° C )

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3 . M e a s u r e t h e r e s is t a n c e o f S S 1 o n / o f f s o le n o id . I f t h e r e s i s t a n c e d o e s n o t m e e t s p e c i fi c a t i o n s in F ig u r e 3 – 9 , r e p la c e s o l e n o i d . 4 . M e a if 3 7 m e e s o le

s u 0 0 t s n o

r e t h e r e s is t a n c e o f S S 2 ( C 6 e n a b le ) S P m o d e l . I f t h e r e s is ta n c e d o e s n o t p e c i fi c a t i o n s i n F i g u r e 3 – 9 , r e p l a c e i d .

C o p y r ig h t ©

2 0 0 9


3 - 1 3

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F i g u r e 3 – 9 . O N / O F F S o l e n o id s — S S 1 a n d S S 2 ( C 6 E n a b l e ) i n 7 – S p e e d M o d e ls 5 . M e a S S 2 m e e s o le

3 - 1 4

s u r e t h e r e s i s t a n c e o f r e t a r d e r a i r s o l e n o i d ( i f e q u i p p e d ) I f t h e r e s i s t a n c e d o e s n o t t s p e c i fi c a t i o n s i n F i g u r e 3 – 1 0 , r e p l a c e n o i d .

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G E N E R A L

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F ig u r e 3 – 1 0 . R e ta r d e r A c c u m u la to r A ir S o le n o id — 6 . M s s s

e a s u re th e e n s o r. If th p e c ifi c a t io n u m p te m p e

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is ta n s is ta o w n re s e

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o f s u m p t e m p e r a t u r e e d o e s n o t m e e t F i g u r e 3 – 1 1 , r e p l a c e o r .

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F ig u r e 3 – 1 1 . T r a n s ID 7 . M e a s u r e th e te m p e ra tu r e n o t m e e t s p e r e p la c e r e t a r 8 . M e s w p ro m e th a re p c lo

r e s is ta s e n s o r. c ifi c a tio d e r te m

n c If n s p e

a s u r e t h e r e s is ta n c e it c h ) a n d P S 2 s w itc h g n o s t ic s fi lt e r life s w a s u re s m o re th a n 4 n 2 0 ,0 0 0 o h m s w ith la c e th e s w it c h . P S 1 s e d ( N C s w it c h e s ) .

e

o f r e t a r d e r t h e r e s i s t a n c e d o e s s h o w n in F ig u r e 3 – 1 1 , r a t u r e s e n s o r . o f ( if itc h o h m th e a n

P S 1 (d e q u ip p ), If th e s c lo s s w itc h d P S 2

ia g e d re e d o p a re

n o s t i c w it h s i s t a n c e o r l e s s e n t h e n n o r m a lly

F o r in s p e c t io n a n d r e p a i r o f e l e c t r ic a l c o m p o n e n t s , r e f e r t o t h e A l l i s o n 4 t h G e n e r a t i o n C o n t r o l s T r o u b l e s h o o t in g M a n u a l T S 3 9 8 9 E N .

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s L u b r a ll m o h e lp s n til t h e

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u r in g fi n a l a s s e m b l y , w i t h t r a n s m i s s i o n fl u i d . t i o n s u r f a c e s a n d f e r r o u s e r v i c e .

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b u ( s s

.

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a s e s o l u tu m s , s s .

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e d g re te m f-c u

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m b l y . D D a lo w m r e ta in p a s , a n d h

u r in e ltin rts , o o k

g a s s e m b l y g p o i n t b u t t - j o i n t - t y p e

c . G re c o m v e g tra n th e

S e a l i n g C o m p o u n d s a n d N o n s o lu b le a s e s . D o n o t u s e g a s k e t - t y p e s e a lin g p o u n d s , fi b r o u s g r e a s e s , o r n o n - s o l u b l e e t a b l e - b a s e d c o o k i n g c o m p o u n d s i n s i d e t h e s m i s s io n , o r w h e r e t h e y c o u l d b e fl u s h e d i n t o t r a n s m is s i o n h y d r a u lic s y s t e m .

d .

C l u t c h e s a n d P i s t o n s . 1 . S o a k e a c h f r i c t i o n - f a c e d c l u t c h p l a t e ( t w o m in u t e m in i m u m ) i n t r a n s m is s io n fl u i d b e f o r e fi n a l a s s e m b l y . 2 . A p p l y a g e n e r o u s a m o u n t o f t r a n s m is s io n fl u id t o t h e p i s t o n c a v i t y b e f o r e fi n a l a s s e m b l y . 3 . A s s e m b l e c lu t c h p l a t e s s o t h e c o n e o f e a c h p l a t e f a c e s t h e s a m e d i r e c t io n .


G E N E R A L e .

O V E R H A U L

T h r e a d e d P l u g s a n d H y d r a u l i c F i t t i n g s .

3 . U s in g a f e e le r g a u g e , m e a s u r e t h e e n d c le a r a n c e o f t h e s e a l r in g . T h e e n d c le a r a n c e m u s t n o t b e l e s s t h a n s p e c i fi c a t io n s a l lo w .

C A U T I O N : • D o n o t u s e T e fl o n ® t a p e o n t h r e a d e d p a r t s . S liv e r s c a n c a u s e t h e t r a n s m i s s i o n t o m a l f u n c t i o n .

4 . If th s p e (2 0 s e a

• I m p r o p e r l y i n s t a l l e d p l u g s o r fi t t i n g s c a n c a u s e le a k a g e a n d c r a c k e d h o u s in g s .

5 . P a c k t h e s e a l r in g a n d it s g r o o v e w it h a lib e r a l a m o u n t o f o i l- s o l u b le g r e a s e .

T h re a d e d p t r a n s m is s io B e s u re th e t ig h t e n a ll p th e a s s e m b T ig h te n o th

lu g s in n s a re s O - r in g lu g s to ly p r o c e e r fi t tin g

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e r s . 3 3 0 b o lts a n g m a n u e th re a d

e e n d c ifi c a t 0 – 3 0 0 lr i n g .

6 . R o ll d ia m B e in th a n o n e g ra d

0 0 P r o d u c t F a m ilie s i g h t - t h r e a d O - r i n g t y p e p l u g s . in lik e - n e w c o n d i t io n a n d t o r q u e v a l u e s s p e c i fi e d i n r e o r in d i s a s s e m b l e d v ie w s . u f fi c i e n t l y t o p r e v e n t l e a k a g e . 0 0 P r o d u c t d 3 7 0 0 S P f a c t u r e d w i t h s .

i. B e in s t a lle o n ly o n s u rfa c e b e a r in g th e s u p

c le io n s °F ) R e p

a ra , b fo r e a

u p th e s e a e te r a n d h g c a re fu l n n e c e s s a ry e n d o f th e u a lly w o r k

a r in g s d w it h o th e ra . If a p w ith a p o r te d

n c e is le s s t h a n m in im u m a k e t h e s e a l r i n g a t 9 3 – 1 4 9 ° C 2 4 h o u r s o r g e t a n e w t 2 a n d 3 .

l r in g t o a b o u o ld it f o r a b o o t to s p re a d , s lid e it o n t o s e a lr in g in t o th e s e a l in to

. I I f a b e a u t a n in s t c e w h ic h r e s s is n o d r ift a n d r a c e .

r in g m u s a lla tio n s is a d ja c e t a v a ila b a h a m m

t h a u t 1 th e th e th e th e

t b le e n t le , e r,

l f i t s f r e e 0 s e c o n d s . s e a l r i n g m o r e h u b . P la c e g r o o v e a n d g r o o v e .

e re m o v e d v e , d r iv e o r to th e m o u n c a r e fu lly s e d r iv in g a g a

o r p r e s s t i n g a t t h e i n s t

L i p - T y p e S e a l s . 1 . W h e n r e p l a c in g lip - t y p e s e a ls , m a k e s t h e s p r in g - lo a d e d lip is to w a r d th e fl u id s e a l e d ( t o w a r d t h e in s id e o f t h e u n it ) . t h e in s id e o f t h e s e a l w it h h ig h te m p e r g r e a s e (M IL - G -3 5 4 5 A o r e q u iv a le n t) to t h e s e a l d u r in g s h a f t in s t a lla tio n a n d to l u b r i c a t i o n d u r i n g i n i t i a l o p e r a t i o n . 2 . T h e c ir c u m f e r w it h a d r y s e a c o lo r e d fo r e a s e a ls d o n o t r b e fo r e in s ta lla

h .

IN F O R M A T IO N

e n la s y e q tio

c e o f s o m e s e a ls n t. T h e s e a l a n t is id e n t ifi c a t io n . P r u ir e a n y a d d it io n a n .

u r e t o b e C o a t a t u r e p r o t e c t p r o v i d e

is p r e u s u a e c o a t l s e a

c o a t e d l l y e d la n t

B u t t - J o i n t S e a l r i n g s . 1 . B u t t - j o i n t s e a l r i n g s r e q u i r e s p e c i a l h a n d l i n g d u r in g a s s e m b l y . T h e s e a l r in g s c o n t a i n m a t e r ia l s t h a t a b s o r b m o i s t u r e f r o m t h e a t m o s p h e r e c a u s in g t h e s e a l r in g t o e x p a n d . T h e s e a lr in g s a r e s h ip p e d in a i r t ig h t p a c k a g e s . D o n o t o p e n t h e s e a le d p a c k a g e u n t i l t h e b u t t - jo i n t s e a l r i n g i s r e a d y t o b e i n s t a l l e d i n t o t h e t r a n s m i s s i o n .

3 – 7 .

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A R N IN G r th e s u m u id . D ir e c o t s u m p m

: A v o i d p w h e n t c o n ta a y re s

c o d r c t w u lt

IN S T A L L IN G ) ( F i g u r e 3 – 1 2 ,

n t a c t w it h t h e a in in g tr a n s m it h th e h o t fl u in b o d ily in ju r

h o t fl u i d i s s io n i d o r t h e y .

C A U T I O N : W h e n e v e r a t r a n s m i s s i o n i s o v e r h a u l e d , e x c h a n g e d , o r h a s u n d e r g o n e r e p a i r s , t h e T r a n s m i s s i o n C o n t r o l M o d u l e ( T C M ) m u s t b e “ R E S E T T O U N A D A P T E D S H I F T S ” . T h i s w ill c a u s e t h e T C M t o e r a s e p r e v i o u s a d a p t i v e i n f o r m a t i o n a n d b e g i n t o a d a p t i n F a s t A d a p t iv e M o d e f r o m t h e b a s e c a l i b r a t i o n . U s e t h e A l l i s o n D O C ® F o r P C – S e r v i c e T o o l ( r e f e r t o t h e A l l i s o n D O C ® F o r P C – S e r v i c e T o o l U s e r ’ s G u i d e G N 3 4 3 3 E N f o r in s t r u c t io n s ) t o “ R E S E T T O U N A D A P T E D S H IF T S ” .

2 . R e m o v e t h e s e a lr i n g f r o m it s p a c k a g e a n d p l a c e i t i n i t s o p e r a t i o n a l p o s i t i o n i n s i d e t h e b o r e t h a t i t w i l l b e s e a l i n g . C o p y r ig h t ©

2 0 0 9


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a . re m tra to

D r a in o v in g n s m is s d r a in o 1 . R v a o C w p A c


F l u i d . D D r a i n t h e t r a n s m i s s i o n fl u i d b e f o r e t h e t r a n s m i s s io n f r o m t h e v e h i c l e . T h e io n s h o u ld b e w a r m a n d t h e fl u id a llo w e d v e r n i g h t .

e m o v e t h e d r a in p lu g f r o m t h e c o n t r o l a lv e m o d u l e . E x a m in e t h e d r a i n e d fl u id n d m a g n e t ic d r a i n p l u g f o r e v id e n c e f c o n t a m i n a t i o n ( r e f e r t o 2 – 1 2 . F L U I D O N T A M I N A T I O N ) . I n s t a l l t h e d r a i n p l u g h e n fl u i d d r a i n i n g i s c o m p l e t e d . I f d r a i n lu g t h r e a d s a r e d a m a g e d , s e e 2 – 1 3 . F L U I D N D F I L T E R C H A N G E P R O C E D U R E f o r o r r e c t i v e a c t i o n .

2 . R e m o v e t h e t r a n s m i s s i o n fi l l t u b e i f i t i n t e r f e r e s w it h t r a n s m is s i o n r e m o v a l . N O T E : A s i g n i fi c a n t a m o u n t o f fl u i d m a y d r a in f r o m a h y d r a u l ic h o s e w h e n it is d i s c o n n e c t e d f r o m t h e t r a n s m is s io n . 3 . D is c o n n e c t a ll h tr a n s m is s io n . R v e h ic le if t h e y in r e m o v a l. P lu g a e n te r in g th e h y d 4 . If a n in t e fro m th e R e m o v e in t e r fe r e o p e n in g s c o o lin g s

3 - 1 8

y d r a u lic h o e m o v e th e te r fe r e w ith l l o p e n in g s r a u lic s y s t e

s e h o th to m

g r a l c o o le r is u s e d , c o o le r a n d d is c o n n e th e h o s e s fro m th e w ith t r a n s m is s io n r e to p r e v e n t d irt fro m y s t e m .

s fro s e s e tra p r e v . d r a in c t c o v e h ic m o v a e n te

F i g u r e 3 – 1 2 . D i s c o n n e c t L o c a t i o n s ( R e t a r d e r E q u i p p e d M o d e ls )

m t h e f r o m t h e n s m i s s i o n e n t d i r t f r o m c o o la le l. r in

o l a n t n t h o s e s . if t h e y P l u g a l l g t h e

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O V E R H A U L

IN F O R M A T IO N 2 . F o r r e t a r d e r m o d e ls , d i s c o n n e c t t h e t r a n s m i s s i o n e x t e r n a l h a r n e s s f r o m t h e t r a n s m i s s i o n f e e d t h r o u g h h a r n e s s , t h e i n p u t s p e e d s e n s o r , t h e o u t p u t s p e e d s e n s o r , t h e r e t a r d e r t e m p e r a t u r e s e n s o r , t h e r e t a r d e r v a l v e b o d y c o n n e c t o r , a n d t h e P T O c o n n e c t o r , i f p r e s e n t ( r e f e r t o F ig u r e 3 – 1 2 a n d F ig u r e 3 – 1 3 . I f u s e d , d i s c o n n e c t t h e t a c h o g r a p h d r i v e . C o v e r t h e h a r n e s s c o n n e c t o r s t o k e e p o u t d i r t . 3 . F o r t r a n s f e r c a s e m o d e ls , t r a n s m is s io n e x t e r n a l h a r n fe e d th r o u g h h a rn e s s c o n n s p e e d s e n s o r, th e tra n s fe r a n d th e P T O c o n n e c t o r , if F ig u r e 3 – 1 3 . C o v e r th e h a t o k e e p o u t d i r t .

c . U n c o u p lin g E n g i n e . 1 . D is c o n tra n s m th e d is w ith r e

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n e c t t is s io n c o n n e m o v in

d i s c o n n e c t t h e e s s f r o m t h e e c t o r , t h e i n p u t c a s e c o n n e c t o r , p r e s e n t ( r e f e r t o r n e s s c o n n e c t o r s

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a f t f r o m t h e o k e . P o s i t i o n i n t e r f e r e n c e .

2 . T r a n s m i s s io n s w i t h P T O s r e q u i r e u n c o u p l i n g o n e o f t h e f o l lo w in g : • P T O

fro m

t h e t r a n s m is s io n

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3 . I f t h e t r a n s m is s io n s u p p o r t s t h e r e a r o f t h e e n g in e , p l a c e a ja c k o r o t h e r s u p p o r t u n d e r t h e e n g i n e . 4 . S e c u r e l y s u p p o r t t h e t r a n s m is s i o n w it h a h o is t , j a c k , o r o t h e r s u i t a b l e r e m o v a l e q u i p m e n t . 5 . R e m o v e a l l b o l t s , n u t s , w a s h e r s , s p a c e r s , a n d s u p p o r t s t h a t a t t a c h t h e t r a n s m i s s i o n t o t h e v e h ic l e a n d t o t h e e n g i n e o r in p u t d r iv e l i n e .

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D is p le o v e t th e

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, d i s c o n n e c t t h e r n e s s f r o m t h e n e c t o r , t h e i n p u t t s p e e d s e n s o r, i f p r e s e n t ( r e f e r t o t t h e t a c h o g r a p h

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2 0 0 9

d .

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o v e th e p p r o x im o m p le te d a p te r r

t r a n s m i s s i o n a w a y f r o m t h e e n g i n e a t e l y 1 1 0 m m ( 4 . 3 3 i n c h ) u n t i l i t i s l y c le a r o f t h e e n g in e . R e m o v e t h e i n g ( i f u s e d ) .

2 . R a i s e o r l o w e r t h e t r a n s m i s s io n a s n e c e s s a r y t o r e m o v e it f r o m t h e v e h i c le .


3 - 1 9

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3 – 8 .

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L IM IT S

R e f e r t o T a b l e 7 – 1 f o r i n f o r m a t i o n c o v e r i n g p a r t s fi t s , c l e a r a n c e s , a n d w e a r l i m i t s .

3 – 9 .

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R e f e r t o T a b l e 7 – 2 f o r s p r i n g i d e n t i fi c a t i o n a n d s p e c i fi c a t i o n s .

3 – 1 0 . A R A a p o a d

T O R Q U E S P E C IF IC A T IO N S

s s e m b l y p r o c e d u r e s i n S e c t i o n 5 . M O D U L E E B U IL D a n d S e c t io n 6 . T R A N S M I S S I O N S S E M B L Y s p e c i f y t h e t o r q u e r e q u i r e m e n t s f o r l l p l u g s , b o l t s , a n d n u t s . T o r q u e v a l u e s a r e a l s o r e s e n t e d w i t h t h e f o l d o u t i l l u s t r a t i o n s i n t h e b a c k f t h i s m a n u a l. T o r q u e v a l u e s s p e c ifi e d a r e f o r d r y s s e m b l y , e x c e p t w h e n o t h e r w is e n o t e d . W a s h a n d r y b o l t s a n d w a s h e r s b e f o r e a s s e m b l y .

3 – 1 1 .

Y o u c a n m e a c o rr F ig u a rra in F

E N G I N E , T R A N S M I S S I O N A D A P T A T I O N R E Q U I R E M E N T S

m u s t m a k e s u re a b e a d a p te d to th e s u r e m e n ts d e s c r ib e c t t r a n s m is s io n - to r e 3 – 1 4 o r A llis o n n g e m e n t o f a d a p ta ig u r e 3 – 1 5 .

3 - 2 0

n e w t r a n s m i s s io n i n s t a l l a t i o n v e h ic le ’s e n g i n e . U s e t h e e d i n t h i s s e c t i o n t o e n s u r e - e n g i n e a d a p t a t i o n . R e f e r t o e x t r a n e t T e c h D a t a . T y p i c a l t io n c o m p o n e n t s is s h o w n

C o p y r ig h t ©


S E C T IO N

3 —

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2 0 0 9

A d a p t a t i o n


3 - 2 1

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F ig u r e 3 – 1 5 . A r r a n g e m e n t o f A d a p t a tio n a . M e a s u r i n g E q u i p m e n t . T h e f o l l o w i n g m e a s u r in g e q u ip m e n t is r e q u i r e d : • 6 0 0 m m

( 2 4 in c h ) p r e c is io n c a li p e r

• 5 0 – 1 0 0 m m • 2 5 – 7 6 m m

( 2 – 4 in c h ) t e le s c o p in g g a u g e ( 1 – 3 in c h ) o u t s id e m ic r o m e t e r

• D ia l in d i c a t o r a n d m o u n t in g a t t a c h m e n t s — b a s e , p o s t s , a n d c la m p s • 0 – 1 5 0 m m

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.

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a n k s n tr ic r p ilo in c h

h a f t H u b P i l o t o r A d a p t e r i t y . T h e c r a n k s h a f t h u b p i l o t o r t h e h u b t c o n c e n t r i c i t y c a n n o t e x c e e d 0 . 1 3 m m ) T I R .

h fl m P

. F le a tn e s e a s u ro d u c

x p la te B o lt H s in th e a r e a o re m e n t r e q u ir e t F a m ilie s tr a n

( 0 – 6 in c h ) d e p t h m ic r o m e te r

b . F l y w h e e l H o u s i n g P i l o t B o r e D i a m e t e r . T h e fl y w h e e l h o u s i n g p i lo t b o r e d i a m e t e r m u s t m e a s u r e 4 4 7 . 6 8 – 4 4 7 . 8 1 m m ( 1 7 . 6 2 5 – 1 7 . 6 3 0 in c h e s ) . c . F l y w h e e l H o u s i n g B o r e R u n o u t . F l y w h e e l h o u s in g b o r e r u n o u t c a n n o t e x c e e d 0 . 5 1 m m ( 0 . 0 2 0 i n c h ) T I R .

i. d e c o a d a x (1

p n a ia .9

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o n v e rte r m e a s u re s in g to th tin g fa c e s h o u ld m in c h e s ) .

d . F l y w h e e l H o u s i n g F a c e S q u a r e n e s s . T h e fl y w h e e l h o u s in g f a c e c a n n o t b e o u t - o f - s q u a r e m o r e t h a n 0 . 5 1 m m ( 0 . 0 2 0 in c h ) T I R . e T d (

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f . C r a n k s h a f t H u b P i l o t o r A d a p t e r S q u a r e n e s s . T h e c r a n k s h a f t h u b o r h u b a d a p t e r c a n n o t b e o u t - o f - s q u a r e m o r e t h a n 0 . 1 3 m m ( 0 . 0 0 5 in c h ) T I R .

3 - 2 2

o l e F l a t n e s s . F l e x p l a t e f t h e b o l t h o l e s is n o t a d f o r t h e 3 0 0 0 a n d 4 0 0 0 s m i s s i o n s .

C o p y r ig h t ©


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c a t i o n . U s in g a f a c e o f t h e t o r q u e c o n v e r t e r fl e x p l a t e q u e c o n v e r t e r 9 . 3 6 – 5 0 . 3 8 m m r e 3 – 1 6 .

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3 – 1 2 .

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D R IV E

3 – 1 3 .

a . F l e x p l a t e I n s p e c t i o n . C h e c k t h e fl e x p l a t e f o r c r a c k s , d i s t o r t i o n , o r e l o n g a t e d b o l t h o l e s . R e p l a c e a w o r n o r d a m a g e d fl e x p la te . b . E n g i n e C r a n k s h a f t E n d P l a y . M a k e s u r e e n g i n e c r a n k s h a f t e n d p l a y i s w i t h i n t h e e n g i n e m a n u f a c t u r e r ’ s s p e c i fi c a t i o n s . N O th e s u r a lig

T E : W h e n a s s e m b l i n g t h e fl e x p l a t e t o c r a n k s h a f t h u b o r h u b a d a p t e r , m a k e e t h e o u t e r fl e x p l a t e b o l t h o l e s a r e n e d .

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C H A S S I S A N D D R IV E L IN E I N S P E C T I O N

I n s p e c t t h e c h a s s i s a n d d r iv e l in e c o m p o n e n t s f o r t h e f o l l o w i n g c o n d i t i o n s , a n d c o r r e c t t h e m a s a p p r o p r i a t e : • T r a n s m i s s io n m o u n t s — b r o k e n o r w o r n - o u t • B o lts a n d o th e r h a r d w a r e — o r i n c o r r e c t

d a m a g e d , m is s in g ,

• I s o la t o r s ( r u b b e r m o u n t s ) — m i s s i n g

d a m a g e d o r

• D r i v e l i n e a n g l e s — r u n o u t , o r b a l a n c e w h i c h d o e s n o t c o n f o r m t o t h e m a n u f a c t u r e r ’s r e c o m m e n d a t io n s • D r i v e l i n e y o k e s l i p jo i n t s :

c . F fl e x p b o lts R e fe in s t a

le x p la te o a n d r to F lle d fl

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o f m o v e m e n t

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• D r iv e lin e m i d s h ip o r h a n g e r b e a r in g s — d a m a g e d o r m is a l ig n e d • U n i v e r s a l j o i n t s : –

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m a n u f a c t u r e r ’ s

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3 - 2 4

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S E C T IO N 4 – 1 . a 3 p a c

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D I S A S S E M B L Y

4 – 2 .

. T h i s s e c t i o n c c t F a m ilie s tr a n s in c lu d e P o w e r T r s . T h e d is a s s e a n d in c lu d e s a ll

o v e r s d is m is s io n s a k e o ff ( P m b ly s e q m o d e l s .

a s . D T O u e

s e m b l y o f i s a s s e m b l y ) p r o v i s io n s n c e is

a .

M o u n t i n g T r a n s m i s s i o n o n R e p a ir S t a n d . W A R N I N G : 3 0 0 0 P r o d u c t F a m i l y t r a n s m is s io n d r y w e i g h t s a r e a s f o l lo w s :

b . P r o c e d u r e s . W h e n a p r o c e d u r e d o e s n o t a p p l y t o y o u r s p e c ifi c m o d e l , g o t o t h e n e x t a p p lic a b l e p r o c e d u r e . c . I l l u s t r a t i o n s . I l l u s t r a t i o n s w i l l n o t a l w a y s s h o w y o u r m o d e l , b u t w h e n a n o p e r a t i o n i i s i d e n t i c a l f o r a l l m o d e l s , t h e c o r r e c t p r o c e d u r e i s s h o w n . d G S g

.

G e n E N E R e c tio n e n e ra l

e r a l In fo r A L O V E R 7 . W E A R i n f o r m a t i o

i o n . R L IN F IT S A N fo llo w

e f e r t o S e c t io n 3 . O R M A T IO N a n d D S P R IN G D A T A fo r s :

P a ra g ra p h

T itle

3 – 2 . T O O L S A N D E Q U I P M E N T

T o o l s a n d E q u i p m e n t

3 – 3 . R E P L A C E M E N T P A R T S

R e p l a c e m e n t P a r t s

3 – 4 . C A R E F U L H A N D L IN G

C a r e f u l H a n d l i n g

3 – 5 . C L E A N I N G A N D I N S P E C T I O N

C l e a n i n g a n d I n s p e c t i o n

3 ( T ( F

R e m o v i n g T r a n s m i s s i o n

– 7 O R R A F ig ig u

.

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3 – 8 . W E A R

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ld o u t 1 9 t 2 0 a t ic s

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D I S A S S E M B L Y O F T R A N S M IS S IO N

B a s e T r a n s m is s io n

2 4 3 k g ( 5 3 5 lb )

W ith P T O

2 6 1 k g ( 5 7 5 lb )

P r o v is io n

W i t h R e t a r d e r

2 7 9 k g ( 6 1 0 l b )

W ith P T O a n d R e t a r d e r

2 9 7 k g ( 6 5 5 lb )

W it h P T O , R e t a r d e r , a n d I n t e g r a l S u m p C o o le r

3 3 6 . 5 k g ( 7 4 0 lb )

3 7 0 0 S P

5 3 0 k g ( 1 1 7 0 lb )

U s e p r o p e r t o o l s a n d l i f t i n g e q u i p m e n t w h e n i n s t a ll i n g o r r e m o v i n g a t r a n s m i s s i o n f r o m t h e r e p a i r s t a n d . 1 . M o u n t J 3 5 9 2 6 h o ld in g fi x t u r e o n t o t h e m a in h o u s in g m o d u l e . 2 . A a b m

tta re a la o u

c h a p la c n c e n t in

S p r in g D a ta

is s n c

t, m a k in o tra n s m d r a is e e o f th e

g s u re is s io n th e tra r e p a ir

lif tin g is p r n s m is s ta n d

a t t a c h m e n t s o p e r l y s io n t o t h e .

3 . S e c u r e t h e t r a n s m i s s io n h o l d i n g fi x t u r e t o J 2 9 1 0 9 r e p a ir s t a n d . 4 . F o r a S te p o n th 3 5 9 2 ( F ig u fi x tu r

W e a r L im it s D a ta

h o e d d , a g fa

3 7 0 0 S P t r a n s m is s io n m o d e l , f o l lo w 1 . I n a d d i t i o n , i n s t a l l J 3 8 5 7 2 fi x t u r e e t r a n s f e r c a s e . C o n n e c t fi x t u r e s J 6 a n d J 3 8 5 7 2 b y in s t a l lin g f o u r b o l t s ( 1 ) r e 4 – 1 ) . S e c u r e t h e t r a n s m i s s i o n h o l d i n g e s t o t h e r e p a i r s t a n d .

t s . R e f e r t o F o ld o u t 5 t h r o u g h - 2 f o r d i s a s s e m b l e d v ie w s a n d t h r o u g h F o l d o u t 3 8 f o r t h e h y d r a u l i c .

C o p y r ig h t ©

2 0 0 9


4 - 1

S E R V IC E

M A N U A L — 3 0 0 0 P r o d u c t F a m i l y — A l l i s o n 4 t h G e n e r a t i o n C o n t r o ls — V O C A T IO N A L M O D E L S in c h ) I D ) , a n d O - r in g ( 1 3 ) ( b r o w n , 6 6 . 3 m m ( 2 . 6 1 0 i n c h ) I D ) . 7 . R e m o v e fl a n g e ( 1 4 ) o r y o k e ( 1 5 ) . 8 . In s p e o r y o a llo w (3 .5 3 d a m a

c t th k e (1 a b le 5 in c g e .

e jo u r n a 5 ) , fo r e d ia m e te h ). In s p R e p la c e

l d ia m x c e s r fo r e c t d if n e

e te r, s iv e w re u s e u s t s h c e s s a

o n fl a n g e ( e a r . M in im is 8 9 . 7 8 m ie ld ( 1 6 ) fo r y .

1 4 ) u m m r

9 . I f p r e s e n t, r e m o v e f o u r M 1 6 x 2 x 8 0 b o lt s ( 7 ) a n d p a r k in g b r a k e a s s e m b l y ( 6 ) . 1 0 . I f p r e s e n t , r e m o v e s e lf - t a p p i n g M 8 s c r e w h a r n e s s b r a c k e t ( 3 ) .

F ig u r e 4 – 1 . 3 7 0 0 S P

R e p a ir S t a n d B r a c k e t s

b . R e m o v a l o f C o m m o n E x t e r n a ll y - M o u n t e d P a r t s ( F i g u r e 4 – 2 ) . 1 . I n s p e c t t r a n s m i s s io n b r e a t h e r 1 f o r d a m a g e o r o b s t r u c t io n . R e m o v e if n e c e s s a r y f o r r e p l a c e m e n t o r c l e a n i n g . 2 . R fi m fi

e m ll t u o d ll t u

o v b e u le b e

e s b r . R s e

e lfa c k e m a l (

ta p e t o v 2 1

p in (2 4 e b ), a

g M ) to ra c k n d d

8 s c r e w ( 2 3 ) r e t a i n i n g t h e m a i n h o u s in g e t ( 2 4 ) , fi l l t u b e ( 2 2 ) , i p s t i c k ( 2 5 ) .

3 . R e m o v e e x p a n d e r p l u g ( 5 ) a n d fi ll t u b e s e a l ( 4 ) f r o m t h e o t h e r fi ll t u b e lo c a t io n o n t h e o p p o s it e s id e o f t h e m a i n h o u s in g m o d u le . N O T E : P r y u n d e r t h e h e a d o f p l u g ( 5 ) , c o m p r e s s t a n g s a n d r e m o v e p lu g ( 5 ) . 4 . R e m re m to th m a n

o v e s ix M o te c o o le r e m a in h o if o ld ( 1 9 ) ,

1 0 m u s o r

x 1 .5 x 3 5 b o lts a n ifo ld ( 1 9 ) , o r i n g m o d u le . R e c o v e r (1 8 ), a n d

(1 7 ) c o v e r m o v e g a s k

re ta (1 8 c o e t (

in in g ) , o le r 2 0 ) .

5 . I f p r e s e n t , r e m o v e b o l t s ( 9 ) ( 3 / 8 - 2 4 , l e n g t h m a y b e 3 / 4 o r 1 – 3 / 8 ) a n d b r a k e d r u m ( 8 ) . N O T E : F o r 3 7 0 0 S P t r a n s m i s s i o n m o d e l , d o n o t r e m o v e y o k e s y e t. R e m o v a l is c o v e r e d in 5 – 1 6 . T R A N S F E R C A S E M O D U L E . 6 . R e m o v e o n e M 1 4 x 2 x 7 0 b o lt ( 1 0 ) , r e t a in e r p l u g ( 1 1 ) , O - r i n g ( 1 2 ) ( b r o w n , 1 2 . 3 m m ( 0 . 4 8 4

4 - 2

C o p y r ig h t ©


a n d


F ig u r e 4 – 2 . C o m m o n c .

E x t e r n a ll y - M o u n t e d P a r t s R e m o v a l

R e m o v a l o f S p e e d S e n s o r s . 1 . If b o s e 1 5 h o

n o n - P T O m o d e l, lt ( 6 ) ( F o ld o u t 6 - 1 n s o r a s s e m b ly ( 3 . 6 m m ( 0 . 6 1 4 in c u s in g m o d u l e .

2 . I f P T O - e q u ip p 2 0 b o lt ( 2 1 ) ( F s p e e d s e n s o r ( 0 . 6 1 4 in c h ) ID c o n v e rte r h o u 3 . F o r x 2 0 o u tp m m th e

n o n -r b o lt u t s p (0 .6 1 re a r c

4 . F o r re b o lt ( 4 s p e e d (0 .6 1 4 re ta rd

re m o v ), re ta ), a n d h ) ID )

e M in e O fro

e t a r d e r m o d e l, (3 2 ) (F o ld o u t 1 e e d s e n s o r a s s 4 in c h ) I D O - r in o v e r m o d u l e .

ta r d e r m o d e l, r e 2 ) ( F o ld o u t 1 1 A s e n s o r a s s e m b in c h ) ID O - r in g e r h o u s i n g .

re m 1 B ) e m g (b

m o v e ), re ta ly ( 3 9 (b ro w

d .

8 x r (5 ) - r in g m th

e d m o d e l, r e m o o ld o u t 6 -2 ), re ta a s s e m b ly ( 1 8 ) , O - r in g ( b r o w n ) s in g m o d u le .

D IS A S S E M B L Y

v e in a n (1

o v , re b ly ro w

1 .2 5 , in p u (b ro w e c o n

M 8 x 1 e r (2 0 ), d 1 5 .6 9 ) fro m

e M ta in (2 9 n )

M 8 in e r ), a n n ) (4

x 2 0 t s p e e d n , v e r t e r

8 x e r ), a (3 0

.2 5 x i n p u t m m t h e

1 . 2 5 ( 3 1 ) , n d 1 5 . 6 ) f r o m

x 1 . 2 5 x 2 0 ( 4 1 ) , o u t p u t d 1 5 .6 m m 0 ) f r o m t h e

C o p y r ig h t ©

2 0 0 9

R e m o v a l o f I n t e g r a l O i l C o o l e r ( F o l d o u t 1 8 - 1 ) . 1 . R s c (

e m e v e o v e 1 .6 6

o v e tw n te e n r (2 3 ), 1 in c h

o M M 1 g a ) ID

1 2 x 1 0 x 1 .5 s k e t ( 2 O - r in g

.7 5 x x 3 5 2 ), a n s (b ro

2 5 b b o lt s d tw w n )

o lts (2 5 o 4 2 (2 6 )

( 2 4 ) a n d ) . R e m o v e . 4 m m .

2 . R e m o v e p l a t e a s s e m b l y ( 2 7 ) a n d f o u r O - r in g s ( 2 8 ) . N S S S P b b h u C u m

O T E : B e g i n n i n g w i t h t r a n s m i s s i o n / N 6 5 1 0 6 7 6 9 1 6 , S / N 6 5 2 0 0 5 6 7 8 3 , / N 6 6 1 0 1 9 9 8 1 2 ( 7 P la t e C o o le r ) a n d / N 6 5 1 0 6 7 6 9 1 7 , S / N 6 5 2 0 0 5 8 8 1 0 ( 1 7 l a t e C o o l e r ) , t h e i n t e g r a l o i l c o o l e r h a s e e n r e d e s ig n e d t o u s e o n e t h ic k O - r in g e t w e e n t h e i n t e g r a l c o o l e r a n d t h e c o o l e r o u s in g . T h e c u r r e n t O - r in g c a n n o t b e s e d w i t h t h e f o r m e r in t e g r a l c o o l e r d e s i g n . u r r e n t n o n - s u m p in t e g r a l c o o l e r s n o w t i l i z e o n l y o n e O - r i n g i n s t e a d o f t w o . F o r o r e in f o r m a t io n s e e S I L 1 3 – W T - 0 6 .


4 - 3

S E C T IO N

4 —


F ig u re

4 – 3 . I n t e g r a l O i l C o o l e r

3 . R e m o v e n in e M 1 0 x 1 . 5 x 2 2 5 b o l t s ( 1 5 ) a n d n in e M 1 0 w a s h e r s ( 1 6 ) . R e m o v e c o o le r h o u s in g ( 7 ) a n d g a s k e t ( 5 ) . 4 . R e m o v e th re e M 1 w a s h e r ( a n d s ix w (7 ) a n d g

th re 0 x 1 1 ), a s h a s k

e M 1 .5 s ix e rs e t (

1 2 x x 2 0 5 M 1 0 (1 6 ). 6 ) .

1 .7 5 w a s x 1 .5 R e m

x 2 3 h e rs x 2 2 o v e

0 b (1 4 5 b c o o

o lts ), b o o lts le r h

C o p y r ig h t ©

D I S A S S E M B L Y

e . R e m o v i n g I n t e g r a l R e t a r d e r S u m p O i l C o o l e r ( F o l d o u t 1 8 - 2 ) .

( 1 3 ) , l t ( 1 2 ) , ( 1 5 ) o u s in g

2 0 0 9

1 . I f u s e d a n d n o t a l r e a d y r e m o v e d , r e m o v e t h e r e t a r d e r a c c u m u l a t o r h o s e f r o m t h e fi t t in g o n c o o l e r m a n i f o l d ( 1 6 ) . 2 . I f n o t a l r e a d y r e m o v e d , r e m o v e in l e t a n d o u t le t w a t e r h o s e s f r o m t h e c o o l e r m a n if o l d .


4 - 4

T R A N S M IS S IO N 3 . S u p p o r t c o o le r ( 7 ) to p r e v e n t it f r o m f r o m m a n if o l d ( 1 6 ) .

f a l l i n g

g .

4 . R e m o v e s i x t e e n M 1 0 x 1 . 5 x 6 0 b o lt s ( 1 ) .

A R ju r y m o e m ); u

N IN G , s e c v in g a n ifo s e c a

: T o u r e ly th e b ld . T re w

h e l p a v o id p e r s o n a s u p p o r t t h e c o o le r b o lts r e t a in in g th e c o o h e c o o le r w e ig h s 2 9 h e n h a n d l in g t h e c o o

R e m o v a l o f T r a n s fe r C a s e M o d u le — 1 . R a R M

5 . R e m o v e s ix M 8 x 1 .2 5 x 2 5 b o lt s ( 5 ) . W in re th lb


l e f o r e l e r t o k g ( 6 4 l e r .

e m n d e m 1 0

o v e (3 ), o v e x 1

h o s e O - r in g s c a v e .5 x 3 5

(1 ) (F s (4 ) n g e p b o lt s

ig u re 4 – 4 a n d (5 ), a u m p (7 ) b (8 ). R e m

), n d y o v

3 7 0 0 S P .

fi ttin g s ( s c re e n r e m o v in e g a s k e

2 ) ( 6 ) . g n in e t ( 9 ) .

2 . S e p a r a t e J 3 5 9 2 6 fi x t u r e ( F i g u r e 4 – 5 ) a n d t h e J 3 8 5 7 2 t r a n s f e r c a s e l i f t i n g fi x t u r e b y r e m o v i n g f o u r b o lt s ( 6 ) .

N O T E : T h e c o o l e r p l a t e a s s e m b l y h a s a p r o v i s i o n t o i n s t a l l t w o M 1 2 e y e b o l t s t o a l l o w s u p p o r t d u r in g d i s a s s e m b l y / a s s e m b l y . 6 . R e m o v e c o o le r p l a t e a s s e m b ly ( 7 ) a n d t w o g a s k e t s ( 6 ) f r o m t h e c o o le r m a n if o l d . 7 . R e m o v e in le t a n d o u t le t w a t e r h o s e a d a p t e r s f r o m c o o l e r m a n i f o l d ( 1 6 ) . R e m o v e t w o g a s k e t s ( 3 ) .

W A R N I N G : T h e t r a n s f e r c a s e m o d u l e a s s e m b l y w e i g h s a p p r o x im a t e l y 2 7 0 k g ( 5 9 5 l b ) . 3 . A tta c a tta c c a s e b o lts tra n s

h

a h o is h m e n ts is p r o p e (2 ) a n d fe r c a s e

t, m a k in g s u r e th a t a r e p la c e d s o th a t t h r ly b a la n c e d . R e m o o n e b o lt ( 7 ) t o d is c o fro m th e m a in tra n s

l i f t i n g e t r a n s f e r v e n i n e t e e n n n e c t t h e m is s io n .

4 . R a i s e t h e t r a n s f e r c a s e t o t h e m o u n t in g f a c e o f t h e r e p a i r s t a n d . 5 . S e c u r e t h e t r a n s f e r c a s e h o l d i n g fi x t u r e t o t h e r e p a i r s t a n d .

8 . R e m o v e p l u g s ( 1 1 ) , ( 1 4 ) , ( 2 5 ) , ( 2 3 ) , ( 2 0 ) , a n d ( 1 7 ) f r o m c o o le r m a n i f o l d . R e m o v e a n d d i s c a r d p l u g O - r i n g s .

6 . R e m o v e g a s k e t ( 4 ) a n d s e le c t i v e s h im ( 1 ) . T h e s e l e c t iv e s h i m i s lo c a t e d in s i d e s h a f t a d a p t e r ( 5 ) .

9 . R o t a t e t h e t r a n s m i s s io n s o t h a t t h e r e t a r d e r is f a c i n g u p . 1 0 . R e m o v e e ig h t M 1 0 x 1 . 5 x 2 1 0 b o lt s ( 9 ) a n d t h r e e M 1 2 x 1 . 7 5 x 2 1 8 b o lt s ( 8 ) . 1 1 . R e m o v e c o o le r m a n if o ld ( 1 6 ) a n d g a s k e t ( 4 ) . f.

R e m o v a l o f P T O ( s ) ( F o l d o u t 1 9 - 2 ) . N O T E : E a c h b o lts , tw o s tu in s t r u c t io n s a a s in g l e r ig h t t r a n s m is s io n P T O is m o u n th e s a m e p ro 1 . R b r (

e m o lt s e m o 6 ) o

o v (7 v e r (

P T O h d s , a n d re fo r a - s id e m h a s m o te d in a c e d u re

a s e ig h t m o u n t in g a g a s k e t. R e m o v a l t r a n s m i s s i o n w i t h o u n t e d P T O . I f y o u r r e t h a n o n e P T O o r t h e d i f f e r e n t lo c a t io n , u s e t o r e m o v e t h e P T O ( s ) .

e e ig h t M 8 x 1 . 5 x 3 5 P T O m o u n t i n g ) o r M 1 0 x 1 . 5 x 3 5 b o l t s ( 1 1 ) . C a r e f u l l y P T O a s s e m b ly ( 8 ) o r ( 1 2 ) a n d g a s k e t 1 0 ) .

2 . I n s p e c t t w o P T O s t u d s ( 5 ) o r ( 9 ) f o r d a m a g e a n d r e m o v e t h e m if n e c e s s a r y .

C o p y r ig h t ©

2 0 0 9


4 - 5

S E R V IC E


W a lb in c 3 lb

A R N I N G : T h e c o n t r o l v a l v e m o d u l e s s e m b ly w e ig h s a p p r o x im a t e ly 2 5 k g ( 5 6 ) . H a n d l e c a r e f u l ly t o a v o id p e r s o n a l ju r y o r c o n t r o l v a lv e m o d u le d a m a g e . T h e o n t r o l v a lv e m o d u l e a s s e m b l y u s e d in a 7 0 0 S P w e ig h s a p p r o x im a t e ly 2 9 k g ( 6 5 ) .

1 . F o r a t w o - in th irty -tw o M c o n t r o l v a lv m o d u le , in c c o v e r s .

F ig u r e 4 – 4 . 3 7 0 0 S P

S c a v e n g e P u m p R e m o v a l

2 . F 1 1 ( b

o r a .5 x 0 0 b 1 ) to o lts

3 . L p b m m

o o s re s o lts o d a in

c h o r 1 0 x 1 e m o d lu d in g

s e v e n .5 x 5 u le (1 th e b

fo u r - in c h s u m p , 5 5 b o lt s ( 3 ) a n d o lts ( 4 ) r e t a in in g th e m a in h o u s in r e ta in in g t h e fi lte

e n c s u re . In s u le b h o u

- in c h s u m 5 b o lt s ( 3 ) to th e m o lts r e ta in

re m o v e s e tw e n ty -fi v e c o n tro l v a g m o d u le , r c o v e r s .

o n t r o l v a lv e m o a t th e r e in fo r c e e r t ja c k b o l t s in o l t h o le s th a t b s in g m o d u l e .

d u le (1 ) d ta b s o to th e c o o t to m a g

p , ) re a in in g v e M lv e in c

re m ta in h o u th e

n M 1 0 m lu d

b y a p r u s e n tro l a in s t

o v e i n g s in g fi l t e r

1 0 x 1 o d u in g

x . 5 x l e t h e

p l y in g ja c k v a l v e t h e

4 . R e m o v e c o n tr o l v a lv e m o d u le a s s e m b ly ( 1 ) a n d g a s k e t ( 2 ) .

F i g u r e 4 – 5 . T r a n s f e r C a s e M o d u l e R e m o v a l h . R e m o v a l o f C o n t r o l V a lv e M o d u le ( F i g u r e 4 – 6 ) . N O T E : T h e c o n t r o l v a l v e m o d u l e o r fi l t e r s m a y c o n t a i n r e s i d u a l t r a n s m is s i o n fl u id . 4 - 6

C o p y r ig h t ©



D IS A S S E M B L Y fl e x p l a t e a d a p t e r b o l t h o l e s . T h e n p l a c e a s c r e w d r iv e r a t a n a n g l e t o p r e v e n t c o n v e r t e r r o t a t io n ( F i g u r e 4 – 7 , V ie w C ) . 5 . R e m o v e M 1 6 x 2 x 3 0 b o lt ( 1 ) u s in g J 3 8 5 6 4 c o n v e r t e r b o lt t o o l . 6 . R e m o v e s h im ( 2 ) lo c a t e d u n d e r b o l t ( 1 ) ( F ig u r e 4 – 7 , V ie w A ) . 7 . A tta c h p o s it io d is ta n c a re fu th e c o

a s lin g n in g th c e fro m lly lift to n v e rte r

8 . P la c e tw o w s p a c e d t o s m o d u le a n d t o c le a r t h e m o d u le , c o n

to th e a d a e a c h rq u e h o u s

o o d e u p p o h ig h w o rk v e r te

e fl e x p p te r c o o th e r. c o n v e r in g ( F ig

la n U te u

n b lo c k s o r t th e to r q e n o u g h fo b e n c h . L o r h u b d o w

t e a d a p t e r b y n e c t io n s a n e q u a l s in g a c h a i n h o i s t , r m o d u l e ( 3 ) o u t o f r e 4 – 7 , V ie w A ) . n th e w u e c o n v r th e c o w e r th e n , o n to

o rk b e n c h e r t e r n v e rte r h c o n v e r te th e b lo c k

, u b r s .

F i g u r e 4 – 6 . C o n t r o l V a l v e M o d u l e R e m o v a l i. R e m o v a l o f T o r q u e C o n v e r t e r M o d u l e ( F i g u r e 4 – 7 ) . 1 . R e m o v e a n y b r a c k e t s in s t a lle d t o p r e v e n t t o r q u e c o n v e r t e r m o v e m e n t . 2 . K e e p t h e t o r q u e c o n v e r t e r c o v e r f r o m t u r n i n g b y u s in g a h e e l b a r , t w o b o l t s a n d a s c r e w d r iv e r ( F ig u r e 4 – 7 , V ie w C ) . 3 . R e m o v e t h r e a d e d p lu g ( 5 ) a n d O - r in g ( 4 ) u s i n g a 3 / 4 i n c h A l l e n w r e n c h . 4 . H o l d t h e t u r b i n e a n d t u r b i n e s h a f t s t a t i o n a r y b y u s in g o n e o f t h e m e t h o d s lis t e d b e l o w : a . I n s e r t a s c r e w d r iv e r in t o t h e v a n e s o n t h e r o t a t in g c lu t c h m o d u l e ( F ig u r e 4 – 7 , V ie w B ) . b . I f t h e c o n t r o l v a l v e m o d u l e is in p l a c e , r e m o v e t h e p l u g ( s ) , i f p r e s e n t , f r o m t h e fi l l t u b e h o l e o r f r o m c o o l e r p o r t s b e f o r e a p p l y i n g l o c k u p a i r p r e s s u r e . A p p l y a i r p r e s s u r e t h r o u g h t h e lo c k u p p r e s s u r e t a p ( F ig u r e 4 – 7 , V ie w D ) a n d u s e a h e e l b a r , s c r e w d r i v e r , a n d b o l t s . I n s e r t t h e h e e l b a r in t o a t o r q u e c o n v e r t e r h o u s i n g b o l t h o l e . I n s e r t t w o b o l t s i n t o t h e C o p y r ig h t ©

2 0 0 9


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F ig u r e 4 – 7 . T o rq u e

C o n v e r t e r M o d u l e R e m o v a l

j . R e m o v a l o f C o n v e r t e r H o u s i n g M o d u l e ( F i g u r e 4 – 8 ) . N b h u r

O T E o lts ( o u s in s e m e m o v

: T h r e 3 ) a re g (1 ). e c h a n e th e s

e c o n v e r te r h o u s in g r e m o v e d fr o m in s id A f te r lo o s e n in g th e i c a l fi n g e r s o r a s im e b o l t s .

re t e c o b o ila r

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1 . R e m o v e t w e n t y M 1 0 x 1 . 5 x 3 5 b o lt s ( 3 ) t h a t r e t a i n c o n v e r t e r h o u s i n g ( 1 ) t o m a i n h o u s i n g m o d u le ( 4 ) . 2 . L i f t s t r a i g h t u p o n c o n v e r t e r h o u s i n g m o d u l e ( 1 ) , o r r e m o v e it u s i n g t h e s a m e s lin g u s e d f o r r e m o v in g t h e c o n v e r t e r m o d u le . 3 . R e m o v e m a in h o u s in g g a s k e t ( 2 ) f r o m c o n v e r t e r h o u s i n g ( 1 ) , o r f r o m m a i n h o u s i n g m o d u le ( 4 ) .

F i g u r e 4 – 8 . C o n v e r t e r H o u s in g M o d u l e R e m o v a l k . R e m o v a l o f R e t a r d e r M o d u le ( F o l d o u t 1 1 A a n d F i g u r e 4 – 9 ) . 1 . R e (F o (3 3 (4 )

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m o v e ld o u t ), fo u , a n d

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s e c u r e r e t a r d e r m o d u l e ( 2 ) ( F i g u r e 4 – 9 ) t o m a i n h o u s i n g ( 3 ) . W w c h 2 . T o r h

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a n h a m (3

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a s s e m b ly lb ) . U s e e l w h i l e e m b l y .

M 1 0 e y e b o lt i n t o t h e r e t a r d e r f t ( 7 ) ( F o l d o u t 1 1 A ) a n d l i f t t h e o d u le ( 2 ) ( F ig u r e 4 – 9 ) f r o m m a i n ) .

3 . R e m o v e r e t a r d e r g a s k e t ( 1 ) ( F ig u r e 4 – 9 ) f r o m m a i n h o u s i n g ( 3 ) o r r e t a r d e r h o u s i n g ( 2 ) .

F i g u r e 4 – 1 0 . T r a n s f e r C a s e A d a p t e r H o u s in g R e m o v a l m . R e m o v a l o f R e a r C o v e r M o d u l e ( F i g u r e 4 – 1 1 ) . 1 . R e m o v e n in e t e e n M 1 2 x 1 . 7 5 x 4 5 b o lt s ( 3 ) . 2 . I f u s e d , r e m o v e t h e r e a r s u p p o r t b r a c k e t . 3 . A t t a c h a s u i t a b le s lin g a n d lif t u p w a r d , r e m o v i n g r e a r c o v e r ( 2 ) . 4 . R e m o v e re a r c o v e r g a s k e t ( 1 ) fro m h o u s i n g ( 4 ) o r r e a r c o v e r ( 2 ) .

m a in

F i g u r e 4 – 9 . R e t a r d e r M o d u l e R e m o v a l l. R e m o v a l o f T r a n s f e r C a s e A d a p t e r H o u s i n g M o d u l e ( F i g u r e 4 – 1 0 ) . 1 . R e m o v e fi ft e e n M x 1 .5 x 1 b o lts ( 5 ) tw o M 1 0

a d 1 2 0 0 , fo x

a p te r x 1 .7 b o lt s u r M 1 1 .5 x

h o u s in g 5 x 4 5 b (6 ), th re 0 x 1 .5 4 0 b o lt s

o e x (

(3 ) b y lts ( 8 ) M 1 2 7 0 b o 7 ) .

re m o v , th re e x 1 .7 5 lts ( 4 ) ,

in M x a

g 1 0 6 0 n d

2 . R e m o v e g a s k e t ( 2 ) . 3 . R e m o v e P 3 c a r r i e r a s s e m b l y ( 1 ) ( F o l d o u t 1 7 - 2 ) b y s lid i n g it u p o v e r t h e m a i n s h a f t .

F ig u r e 4 – 1 1 . R e a r C o v e r M o d u l e R e m o v a l

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2 0 0 9


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n .


R e m o v a l o f M a in S h a f t M o d u l e ( F i g u r e 4 – 1 2 ) . 1 . R e m o v e t h r u s t b e a r in g ( 3 ) a n d s h im t h e m a in s h a f t m o d u l e .

6 . L i f t P 1 p l a n e t a r y m o d u le ( 1 ) ( F ig u r e 4 – 1 4 ) f r o m t h e m a i n h o u s in g m o d u l e .

( 2 ) f r o m

2 . L if t m a in s h a ft m o d u le ( 1 ) o u t o f t h e t r a n s m i s s i o n .

F ig u r e 4 – 1 3 . P 2 M o d u le a n d C 5 C l u t c h P a c k R e m o v a l

F i g u r e 4 – 1 2 . M a in S h a f t M o d u l e R e m o v a l o . R e m o v a l o f P 2 M o d u l e , C 5 C l u t c h P l a t e s , a n d P 1 M o d u l e ( F i g u r e 4 – 1 3 , F i g u r e 4 – 1 4 ) . 1 . L i f t P 2 p l a n e t a r y m o d u l e ( 1 ) ( F ig u r e 4 – 1 3 ) f r o m t h e m a in h o u s in g m o d u l e . 2 . L i f t C 5 c lu t c h p a c k f r o m t h e m a i n h o u s i n g m o d u l e — s e v e n f r i c t i o n p l a t e s ( 3 ) a n d e i g h t s t e e l r e a c t i o n p l a t e s ( 2 ) . 3 . V is u a lly in s p e c t a ll f r ic t io n a n d s t e p la t e s f o r d a m a g e o r e x c e s s iv e w fr ic t io n p l a t e s o r s t e e l r e a c t io n p la p e r c e iv a b le w e a r o r d is to r t io n , m e th i c k n e s s o f e a c h f r ic t io n p l a t e ( 3 ) a llo w a b l e t h ic k n e s s f o r r e u s e is 2 ( 0 . 1 1 4 in c h ) . M e a s u r e th e o il g r o o e a c h fr ic tio n p la t e . M in im u m a llo w d e p t h fo r r e u s e is 0 . 2 0 m m ( 0 . 0 0 8

e l r e a c t i o n e a r . I f t e s h a v e a s u r e t h e . M i n i m u m . 9 0 m m v e d e p t h o f a b l e g r o o v e in c h ) .

4 . M e a s u r e t h i c k n e s s o f e a c h s t e e l r e a c t i o n p l a t e ( 2 ) . M i n i m u m a l l o w a b l e t h i c k n e s s f o r r e u s e i s 2 . 3 6 m m ( 0 . 0 9 3 in c h ) . 5 . M e a s u re th a llo w a b le c in c h ) . I f p la re p la c e a s 4 - 1 0

e c o n e o n e fo r te s d o n e c e s s

o f e a c h p la t e . M a x im u m r e u s e is 0 . 4 1 m m ( 0 . 0 1 6 n o t m e e t s p e c ifi c a t io n s , a r y . C o p y r ig h t ©

F ig u r e 4 – 1 4 . P 1 M o d u le R e m o v a l p . R e m o v a l o f F r o n t S u p p o r t / C h a r g i n g P u m p M o d u l e a n d R o t a t i n g C l u t c h M o d u l e ( F i g u r e 4 – 1 5 , F i g u r e 4 – 1 6 ) . 1 . R e m fi v e th a t m o d

o v M 1 r e t u le

e s ix M 0 x 1 .5 a in fro n (3 ) to


1 0 x t s th e

x 1 .5 x 3 5 b o lt s u p p o rt a m a in h o

6 0 b (2 ) ( n d c u s in

o lt s ( 1 ) a n d F i g u r e 4 – 1 5 ) h a r g i n g p u m p g .

T R A N S M IS S IO N 2 . L i f t f r o n t s u p p o r t a n d c h a r g i n g p u m p m o d u l e ( 3 ) a w a y f r o m t h e t u r b i n e s h a f t . 3 . U s in g a h o i s t a n d a M 1 6 e y e b o l t , l i f t t u r b i n e s h a f t a n d r o t a t i n g c l u t c h m o d u l e ( 1 ) ( F i g u r e 4 – 1 6 ) f r o m t h e m a in h o u s in g m o d u l e .

D IS A S S E M B L Y q . R e m o v a l o f C 3 /C 4 C lu t c h A s s e m b ly F r o m M a i n H o u s i n g M o d u l e ( F i g u r e 4 – 1 7 ) . C A U T I O N : M a k e s u r e t h a t t h e m a i n h o u s in g a s s e m b l y is h o r iz o n t a l w h e n r e m o v in g t h e C 3 / C 4 c lu t c h a s s e m b l y . 1 . R e m o v e tw e lv e M 1 0 x 1 .5 x 3 5 m m b o lt s 3 r e t a i n i n g C 3 / C 4 c lu t c h a s s e m b l y ( 1 ) i n m a i n h o u s in g m o d u le ( 2 ) . 2 . R e m o v e C 3 / C 4 c lu t c h a s s e m b ly ( 1 ) b y s lid i n g it o u t o f t h e in p u t e n d o f m a i n h o u s in g m o d u le ( 2 ) . 3 . R e m o v e t h e m a in h o u s in g f r o m s t a n d f o r c l e a n i n g .

t h e r e p a ir

4 . I n s p e c t t h e m a i n h o u s in g c lu t c h p l a t e s p l in e s . M a x im u m a l lo w a b l e w e a r f o r r e u s e is 1 . 1 5 m m ( 0 . 0 4 5 in c h ) .

F i g u r e 4 – 1 5 . F r o n t S u p p o r t / O i l P u m p M o d u le R e m o v a l C A U T I O N : C C a r e f u l l y p l a c e r o t a t i n g c l u t c h m o d u l e ( 1 ) ( F i g u r e 4 – 1 6 ) o n t h e w o r k b e n c h a n d p r e v e n t it f r o m r o l lin g o f f t h e b e n c h .

F i g u r e 4 – 1 7 . C 3 /C 4 C l u t c h M o d u l e R e m o v a l

F i g u r e 4 – 1 6 . R o t a t i n g C l u t c h M o d u l e R e m o v a l

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2 0 0 9


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M A N U A L — 3 0 0 0 P r o d u c t F a m i l y — A l l i s o n 4 t h G e n e r a t i o n C o n t r o ls — V O C A T IO N A L M O D E L S N O T E S

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5 – 3 .

s e c tio n c o v ilie s tr a n s m e P o w e r T a k e d is a s s e m c lu d e s a ll m

e r s th e is s io n s e o ff ( P b ly s e q o d e l s .

d i s a s s e m b l y o f . D i s a s s e m b l y T O ) p r o v i s io n s u e n c e is

b . P r o c e d u r e s . W h e n a p r o c e d u r e d o e s n o t a p p l y t o y o u r s p e c ifi c m o d e l , g o t o t h e n e x t a p p lic a b l e p r o c e d u r e . c . I l l u s t r a t i o n s . I l l u s t r a t i o n s w i l l n o t a l w a y s s h o w y o u r m o d e l , b u t w w h e n a n o p e r a t i o n i s i d e n t i c a l f o r a l l m o d e l s , t h e c o r r e c t p r o c e d u r e i s s h o w n .

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D i s a s s e m b l y ( F o l d o u t 5 ) . 1 . B e fo re n o te b lin e a c a s s e m w ill m a a s s e m

d is a s s e m b a la n c e m a r ro s s th e c o b ly w it h a s k e s u re th e b le d a n d r e

2 . P la c e to fl a t s u rfa d o w n w a o n w o o d ta n g s fro

4 . C a a s

o S e c tio n 3 . G E N E R A L O V E R H A U L M A T IO N a n d S e c t io n 7 . W E A R L IM I T S A N D G D A T A f o r g e n e r a l o v e r h a u l in f o r m a t io n a s : P a r a g r a p h

a .

T O R Q U E C O N V E R T E R

rq u c e rd . e n m

e c o n v w it h t h S u p p o b lo c k s c o n t a c

lin g th e to k s (F ig u re n v e rte r c o c r ib e . A lig to r q u e c o d u c e b a la

r q u e c o n v e r t e r , 5 – 1 0 ) o r m a r k a v e r t o t h e p u m p n i n g t h e s e m a r k s n v e r t e r i s c o r r e c t l y n c e p r o b le m s .

e r e rt th t in

u le ( 3 ) o n a p d r iv e t a n g s v e r t e r a s s e m b l y t h e o il p u m p d r iv e o r k b e n c h .

te r m o d o il p u m th e c o n a t k e e p g th e w

3 . R e m o v e t h i r t y - s i x M 8 x 1 . 2 5 n u t s ( 4 ) f r o m t h e O D o f t o r q u e c o n v e r t e r c o v e r a s s e m b l y ( 5 ) .

d . F o l d o u t s . R e f e r t o F o l d o u t 5 t h r o u g h F o l d o u t 1 9 - 2 f o r d i s a s s e m b l e d v i e w s a n d t o r q u e s p e c i fi c a t i o n s .

5 – 2 .

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a r s s s s e a

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e p a r a t e t h e t o r q u e c o n v e r t e r c o v e r ( 5 ) f r o m t h e t o r q u e c o n v e r t e r p u m p ( 3 1 ) , a v o i d i n g d a m a g e t t o t h e i r r f a c e s .

5 . R e m o v e t h e la r g e s e a l ( 3 0 ) u s e d b e t w e e n t h e c o v e r a s s e m b ly a n d p u m p a s s e m b ly . 6 . R e m o v e t u r b in e a s s e m b ly ( 1 7 ) . R e m o v e s e a l r i n g ( 1 5 ) f r o m t h e h u b o f t h e t u r b i n e a s s e m b ly . M e a s u r e t h e O D o f t h e t u r b in e h u b . M in i m u m a l lo w a b l e d i a m e t e r f o r r e u s e is 6 1 . 3 4 m m ( 2 . 4 1 5 i n c h ) . P la c e s e a l r i n g ( 1 5 ) i n t o t h e b o r e o f t o r q u e c o n v e r t e r c o v e r ( 7 ) w h e r e i t i s l o c a t e d d u r i n g o p e r a t i o n . M e a s u r e t h e s e a l r i n g I D . M a x i m u m a l l o w a b l e s e a l r i n g I D f o r r e u s e is 5 6 . 7 5 m m ( 2 . 2 3 4 in c h ) . 7 . If a n IN 5 5

re p la c e m e n d in s p e c t, p S P E C T IO N m m (2 .1 6 5

t is e r , th in c

n e c 3 – 5 ru s t h )ID

e s s a ry , re m o . C L E A N IN G b e a r in g a s s e , a n d s ta r w a

v e A N D m b ly 1 8 - s h e r ( 1 9 ) .

8 . R e m o v e s ta t o r a s s e m b ly ( 2 0 ) . R e m o v i n g T r a n s m i s s i o n

W e a r L im i t s D a t a S p r in g D a ta

9 . R A a o

e m o v e N D IN S n d 8 0 m f th e s ta

a n d in s p e c t, p e r 3 – 5 . C L E A N I N G P E C T I O N , p u m p t h r u s t b e a r i n g ( 2 9 ) m s e le c t iv e s h im ( 2 8 ) f r o m t h e b a c k t o r .

1 0 . R e m o v e r e t a i n i n g r in g ( 2 1 ) . 1 1 . R e m o v it s th i c k M in im u 1 1 .6 8 m

e s n e m m

ta t o r th s s a d ja a llo w a b (0 .4 6 0

r u s t p l a t e ( 2 2 ) a n d m e a s u r e c e n t t o t h e s t a t o r r a c e . l e t h i c k n e s s f o r r e u s e i s in c h ) .

1 2 . R e m o v e a n d in s p e c t s t a t o r t h r u s t w a s h e r ( 2 3 ) . M a x im u m s t e p w e a r a llo w e d is 0 . 2 5 m m C o p y r ig h t ©

2 0 0 9


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( 0 . 0 1 0 in c h ) . S t a t o r t h r u s t w a s h e r m a y b e t u r n e d o v e r o r r e p l a c e d if s t e p w e a r e x c e e d s s e r v i c e l i m i t s . 1 3 . R e m o v e a n d in s p e c t s t a t o r r a c e s p r in g s ( 2 5 ) ( r e f e r t o T a b le 7 – 2 C h a r t ) , a n d r o l le r s ( 2 6 ) . A ls o in s th ru s t w a s h e r u n d e r c a m (n o t s M a x im u m s t e p w e a r a llo w e d is ( 0 . 0 1 0 in c h ) . S ta t o r t h r u s t w a s h tu r n e d o v e r o r r e p la c e d if s t e p w s e r v i c e l i m i t s . 1 4 . F ro m c o n (6 ), re m o re ta in in g c o n v e rte r

v e v e th e c o

rte r th ir lo c v e r

( 2 4 ) , t h i r t e e n f o r S p r i n g p e c t s t a t o r h o w n ) . 0 .2 5 m m e r m a y b e e a r e x c e e d s

c o v e r a n d b u s h in g a s s e m b l y t y M 8 x 1 . 2 5 x 3 0 b o l t s ( 1 4 ) k u p c l u t c h b a c k p l a t e ( 1 3 ) t o ( 7 ) .

1 5 . R e m o v e l o c k u p c lu t c h M e a s u r e th e th ic k n e s s s u r f a c e . M in im u m a llo w r e u s e is 8 .5 8 m m ( 0 .3 3 c o n e o f b a c k p la te ( 1 3 ) . c o n e f o r r e u s e is 0 . 1 5 m

b a c k p la t e o f th e b a c a b le t h ic 8 in c h ) . M M a x im u m m (0 .0 0 6

( 1 3 ) . k p la t e w k n e s s fo e a s u re a llo w a in c h ) .

e a r r t h e b l e

1 6 . R e m o v e l o c k u p c lu t c h / d a m p e r ( 1 2 ) f r o m c o n v e r t e r c o v e r ( 7 ) . M e a s u r e t h e t h i c k n e s s a c r o s s t h e l o c k u p c l u t c h f r i c t i o n s u r f a c e s . M i n i m u m a l l o w a b l e t h i c k n e s s f o r r e u s e i s 0 . 6 2 5 m m ( 0 . 0 2 5 i n c h ) p e r s id e . C h e c k f o r d i s t o r t i o n o f t h e l o c k u p c l u t c h f r i c t i o n s u r f a c e s . M a x i m u m a l l o w a b l e d i s t o r t i o n f o r r e u s e i s 0 . 5 1 m m ( 0 . 0 2 0 i n c h ) . C h e c k s p li n e w e a r b e t w e e n t h e t u r b i n e a n d t h e lo c k u p c lu t c h d a m p e r . M a x i m u m a l lo w a b l e s p l in e w e a r f o r r e u s e is 0 . 3 8 m m ( 0 . 0 1 5 in c h ) . 1 7 . R e m o v e l o c k u p c lu t c b y u s in g a ir p r e s s u r e th e c o n v e rte r c o v e r a R e m o v e O D s e a lr i n g c lu t c h p is to n . M e a s u lo c k u p c lu t c h p i s t o n . th ic k n e s s fo r r e u s e is

2 1 . I f r e p la c e m e n t is n e c e s s a r y , r e m o v e p u m p t h r u s t w a s h e r ( 3 2 ) I D 8 0 . 1 5 m m ( 3 . 1 5 in c h ) f r o m t h e p u m p .

h p is to n a s s e m b ly ( 1 0 ) o r b y l i g h t l y s t r i k i n g g a i n s t a fl a t s u r f a c e . ( 1 1 ) f r o m t h e lo c k u p r e t h e t h i c k n e s s o f t h e M in i m u m a l lo w a b l e 5 . 7 1 m m ( 0 . 2 2 5 in c h ) .

2 2 . I f b o l t r e p l a c e m e n t i s n e c e s s a r y , r e m o v e d a m a g e d M 8 x 1 . 2 5 x 2 5 T - h e a d b o lt ( s ) ( 3 4 ) f r o m t h e O D o f t o r q u e c o n v e r t e r p u m p ( 3 3 ) . 2 3 . E x a m in e t o r q u e c o n v e r t e r p u m p a s s e m b ly ( 3 1 ) f o r c r a c k s , m i s s in g v a n e s , o r a l o o s e t o r u s r i n g . 2 4 . In s a s w e w a b .

p e c s e m a r. s h e

t s b ly M a r is

ta t o r w a s h e r in s ( 2 7 ) f o r v is u a l d x im u m a llo w a b l e 0 .2 5 m m (0 .0 1 0

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in s p e c t c o n v m a llo w a b le m ( 2 .4 2 2 in c h a m m e r a n d b e y o n d s e rv

e r te r c b u s h in h ). R e c h is e l ic e lim

o v e r b u s h in g g ID fo r re u s e m o v e th e b u s i f v is u a l l y d a m i t s .

N S S S S s w p c c 8 S

O T E : B e g i n n i n g w i t h S /N 6 5 2 0 0 8 3 0 9 3 , S /N 6 /N 6 6 2 0 0 0 5 8 2 1 , S /N 9 /N 9 3 2 0 0 0 6 2 3 1 , S /N 9 /N 9 4 2 0 0 0 7 5 6 0 , th e m e a ls h a s b e e n m o d i fi e d i t h D E X R O N ® - V I fl u i d s r io r to th e a b o v e s e r ia l o m p a tib le w ith D E X R O o m p a tib ility c a n b e id e n c o lo r m a r k s o n t h e f a c IL 6 - W T - 0 7 fo r m o r e in

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6 5 1 0 7 1 7 2 8 1 , 6 1 0 2 2 0 9 9 0 , 3 7 0 0 0 7 6 6 1 , 4 7 0 0 0 6 0 8 0 , a n d a t e r i a l o f s p e c ifi c t o b e c o m p a t ib le . T r a n s m i s s i o n s n u m b e r s a r e n o t N ® - V I fl u i d s . S e a l t i fi e d b y a " D 6 C " o r e o f t h e s e a l. S e e f o r m a t io n .

1 . I n s t a l l s t a t o r r a c e ( 2 4 ) i n t o s t a t o r a n d c a m a s s e m b l y ( 2 7 ) 2 . In s t a ll t h ir t e in t o s ta t o r a s p r in g s a n d p o c k e ts a s t h e r o l l e r s .

e n s p r in g s ( 2 n d c a m a s s e r o l le r s a r e in s h o w n in ( F ig

( 8 ) . is h in g a g e d

2 0 . R e m o v e i n n e r l o c k u p p i s t o n s e a l r i n g ( 9 ) f r o m t h e h u b o f t h e c o n v e r t e r c o v e r ( 7 ) .

5 - 2

r a n d c a m a g e o r s te p p w e a r o f t h r u s t h ) .

A s s e m b l y ( F o l d o u t 5 ) .

1 8 . R e m o v e t h r u s t b e a r in g ( 1 6 ) . 1 9 . V is u M a x 6 1 .5 u s in o r w

ta to a m s te in c


5 ) a n m b ly s t a l le u re 5

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l le r s ). B e th e . L u b

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O T E : B e g i n n i n g w i t h S /N 6 5 2 0 0 8 3 0 9 3 , S /N 6 /N 6 6 2 0 0 0 5 8 2 1 , S /N 9 /N 9 3 2 0 0 0 6 2 3 1 , S /N 9 /N 9 4 2 0 0 0 7 5 6 0 , th e m e a ls h a s b e e n m o d i fi e d i t h D E X R O N ® - V I fl u i d s r io r to th e a b o v e s e r ia l o m p a tib le w it h D E X R O o m p a t ib ility c a n b e id e n c o lo r m a r k s o n t h e f a c I L 6 - W T - 0 7 f o r m o r e in

9 . In s ta ll lo w ith p a r lo c k u p p c o v e r (7

F i g u r e 5 – 1 . S t a t o r R o l l e r / S p r i n g I n s t a l l a t i o n

c k u t n u is to ) (F

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d a m p e r ( 1 2 ) ( F i g u r e 5 – 2 ) , w n ( F ig u r e 5 – 3 ) t o w a r d s b l y , i n t o t o r q u e c o n v e r t e r 4 ) .

3 . I n s t a l l s t a t o r t h r u s t w a s h e r ( 2 3 ) a n d t h r u s t p l a t e ( 2 2 ) o n t o s t a t o r a n d c a m a s s e m b l y ( 2 7 ) . 4 . I n s t a l l r e t a i n i n g r i n g ( 2 1 ) . 5 . L u b r i c a t e s t a r w a s h e r ( 1 9 ) , a n d i n s t a l l i t o n t o t h e s t a t o r . 6 . I f r e m o v e d in 5 – 3 a . D is a s s e m b l y ( F o l d o u t 5 ) , S t e p 1 9 , p r e s s a n e w b u s h in g ( 8 ) ( 6 1 . 4 5 m m ( 2 . 4 2 in c h ) I D ) in t o t h e b o r e , fl u s h t o 0 . 0 4 0 b e l o w fl u s h , o f t o r q u e c o n v e r t e r c o v e r ( 7 ) u s i n g J – 3 8 5 6 6 B u s h i n g I n s t a l le r a n d J – 8 0 9 2 D r iv e H a n d l e . I n s e r t t u r b i n e a s s e m b l y ( 1 7 ) o n t o t h e n e w b u s h in g a n d c h e c k f o r f r e e d o m o f r o t a t i o n . A f t e r t h e t r i a l fi t , r e m o v e t h e t u r b i n e f r o m t h e f r o n t c o v e r . 7 . In in c F

s ta ll th r u c h ) ID b la o v e r a n d ig u r e 3 – 4

8 . In s ta ll c o lo r c to r q u e s e a l r in a s s e m

lo c k o d e c o n g (1 b ly

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u p p is to n s e a l d w it h g r e e n m v e r te r c o v e r (7 1 ) o n th e O D o ( 1 0 ) . In s t a ll th e

) 6 3 . 2 m m ( 2 . 4 8 a g a i n s t c o n v e r t e r m b ly ( 6 ) . S e e . r in g ( 9 ) , 8 6 . 9 m a rk s , o n th e h ) a n d lo c k u p p f lo c k u p c lu t c h lo c k u p c lu tc h

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1 3 . In s ta l l s e a l r in g ( 1 5 ) o tu r b in e a s s e m b ly (1 7 c o n v e r te r tu r b in e a s s c o n v e r te r c o v e r a s s e th e b a la n c e m a r k o n b a la n c e m a r k o n th e ( F i g u r e 5 – 6 ) .

n t o t o r q u e c o n v e r t e r ) a n d i n s t a l l t o r q u e e m b l y ( 1 7 ) i n t o t o r q u e m b l y ( 5 ) a l i g n i n g t h e t u r b i n e w it h t h e l o c k u p c lu t c h d a m p e r

F i g u r e 5 – 4 . T o r q u e C o n v e r t e r C o v e r a n d L o c k u p C l u t c h 1 0 . I n s t a l l l o c k u p c l u t c h b a c k p l a t e ( 1 3 ) . 1 1 . I n s t a l l t h i r t y M 8 x 1 . 2 5 x 3 0 b o l t s ( 1 4 ) . T i g h t e n b o l t s t o 3 0 – 3 5 N ∙ m ( 2 2 – 2 6 lb f t ) . 1 2 . If r e m S te p (1 8 ) c o n v

o v e d in 7 , in s t a (5 5 m m e r te r tu r

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( F ig u r e 5 – 8 , F ig u r e 5 – 9 ) . S e e F i g u r e 3 – 4 f o r r e f e r e n c e .

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a l l t h i r t y - s ix M 8 x 1 4 ) a r e in s t a l le d in to s s e m b ly (3 3 ) fl a n g e a s h e r ( 3 2 ) in t o t o r q ly ( 3 1 ). S ta k e th r u s v e r t e r . S ta k e a t s ix s

3 6 8 m m c o n v e rte o r s c rib e to rq u e c o o f to r q u e

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x 2 5 T - h e a d u e c o n v e r t e r e m o v e d , in s t a l l o n v e r t e r p u m p s h e r ( 3 2 ) in t o a l l y - s p a c e d

O - r in g W ith b d ( F ig u p a s s e o v e r a s

( 3 0 ) o n t o a la n c e r e 5 – 1 0 ) , m b l y ( 3 1 ) s e m b l y ( 5 ) .

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1 8 . I n s t a l l f o u r M 8 x 1 . 2 5 n u t s ( 4 ) , o n t o f o u r e v e n l y s p a c e d M 8 x 1 . 2 5 x 2 5 T - h e a d b o lt s ( 3 4 ) . T i g h t e n t h e n u t s t o 3 0 – 3 5 N ∙ m ( 2 2 – 2 6 lb f t ) . 1 9 . U s to p o f T h

in g o f to r q is is

a d e p th e c o u e c o d im e

t h m ic r o m e t e r , m e a s u r e f r o m t h e n v e r t e r h u b t o t h e t h r u s t s u r f a c e n v e r t e r t u r b i n e a s s e m b l y ( 1 7 ) . n s i o o n n A ( F i g u r ee 5 – 1 1 ) .

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2 0 . I n s e r t J – 3 8 5 4 8 i n t o t h e c o n v e r t e r c o v e r a n d p la c e o n a fl a t s u r f a c e . R e p e a t t h e s a m e m e a s u r e m e n t a s in S t e p 1 9 . T h is is d im e n s io n B . . 2 1 . S u b t r a c t d i m e n s i o n B B f r o m d i m e n s i o n C C . .

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i o n C d o n o f 0 .0 8 b a c k to 5 ) a n d d ll th e c o r – 2 3 . If d

e s n o t e q u a l t h e “ N O S T E P ” – 0 . 3 5 m m ( 0 . 0 0 3 – 0 . 0 1 4 5 – 3 a . D is a s s e m b ly i s a s s e m b l e t h e c o n v e r t e r r e c t s h i m a t S t e p 1 5 . R e p e a t i m e n s i o n C C e q u a l s t h e “ N O

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0 .0 0 0 m m

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S T E P ” d i m e n s i o n , c l e a r a n c e i s c o r r e c t , g o o n t o S t e p 2 4 . 2 4 . In s ta n u ts b o lts (2 2 –

ll th e (4 ) o (3 4 ) 2 6 lb

r e m a i n i n g t h i r t y - t w o M 8 x 1 . 2 5 n to c o n v e r t e r p u m p M 8 x 1 .2 5 x 2 5 . T i g h t e n a l l t h e n u t s t o 3 0 – 3 5 N ∙ m f t ) .


M O D U L E 5 – 4 .

a .

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T O R Q U E C O N V E R T E R H O U S IN G M O D U L E ( M o d e ls W it h P T O P r o v i s i o n )


M o d u l e D i s a s s e m b l y ( F o l d o u t 6 - 2 ) . N O T E : B e g i n n i n g J a n u a r y 2 0 0 6 a n d w i t h S / N 6 5 1 0 6 3 3 3 0 7 a n d S / N 6 5 2 0 0 5 8 7 5 5 , t h e in p u t s p e e d s e n s o r h a s b e e n r e d e s ig n e d . S e e F ig u r e 3 – 7 t o id e n t i f y f o r m e r o r c u r r e n t s p e e d s e n s o r t y p e s . S e e T a b le 3 – 2 f o r a l l s p e e d s e n s o r s p e c i fi c a t i o n s o f f o r m e r a n d c u r r e n t t y p e . S e e T S 3 9 8 9 f o r D T C , c o n n e c t o r , a n d c i r c u i t i n f o r m a t i o n . I n f o r m a t io n a b o u t t h i s c h a n g e m a y a l s o b e f o u n d in S I L 5 - W T - 0 6 . 1 . I f n o t p r e v io u s ly r e m o v e d , r e m o v e in p s e n s o r M 8 x 1 .2 5 x 2 0 r e ta in in g b o lt s e n s o r r e t a in in g b r a c k e t ( 2 0 ) , in p u t s s e n s o r a s s e m b ly ( 1 8 ) , a n d O - r in g ( 1 C h e c k in p u t s p e e d s e n s o r r e s is ta n c e to 3 – 5 . C L E A N IN G A N D IN S P E C T IO

u t s p e e d ( 2 1 ) , p e e d 9 ) * . . R e f e r N .

2 . R e m o v e a n d in s p e c t b r e a t h e r a s s e m b ly ( 2 8 ) o r b r e a t h e r a d a p t e r ( 2 9 ) u s in g a t h in 1 4 m m w r e n c h . 3 . If p c o v 2 5 c o v

re s e n e r(s ) b o lt s e r (s )

t, r (2 5 (2 6 (2 5

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c .

k e o f f ( P T O ) n M 1 0 x 1 . 5 x R e m o v e P T O 2 4 ) .

t th e r d a m u m a in c h

b e a r i n g b o r e o f c o n v e r t e r h o u s i n g a g e . M e a s u r e t h e b e a r in g b o r e — llo w a b le I D f o r r e u s e is 1 4 0 . 0 6 m m ) .

b . D is a s s e m b ly o f th e B e a rin g A s s e m b l y .

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1 . R e m o v e s e a lr in g ( 8 ) ( 1 7 8 . 8 m m ) f r o m b e a r in g r e t a i n e r ( 7 ) . R e m o v e o i l s e a l ( 4 ) u s i n g J – 2 4 1 7 1 - A S lid e H a m m e r a n d J a w S e t.

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r d a m a u s h in g ). If re e b u s h

3 . In s p e c t th (7 ) fo r d a b o re — m a 1 4 0 .0 6 m

e b e a r in g b o r e o f b e a r in g r e t a i n e r m a g e . M e a s u r e t h e b e a r i n g x im u m a l l o w a b l e I D f o r r e u s e i s m ( 5 . 5 1 4 in c h ) .

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5 . R e m o v e b e a r in g r e t a i n e r a s s e m b l y ( 3 ) a n d P T O g e a r a s s e m b l y ( 9 ) . I f n e c e s s a r y , u s e ja c k b o lt s t o l o o s e n t h e b e a r in g r e t a i n e r a s s e m b l y . s p e c 2 ) fo a x im .5 1 4

2 . In s p e c t b u M a x im u m is 7 5 . 5 m m n e c e s s a ry h a m m e r a

1 . R e m o v e r e t a in in g r in g ( 1 5 ) . R e m o v e 6 8 m m o il p u m p d r iv e h u b ( 1 3 ) f r o m P T O g e a r ( 1 2 ) .

4 . R e m o v e t e n M 1 0 x 1 . 5 x 3 5 b o l t s ( 2 ) h o l d i n g b e a r i n g r e t a i n e r a s s e m b l y ( 3 ) i n t o c o n v e r t e r h o u s i n g ( 2 2 ) .

6 . In (2 m (5

O T E : B e g i n n i n g w i t h S / N 6 5 1 0 7 1 7 2 8 1 , / N 6 5 2 0 0 8 3 0 9 3 , S / N 6 6 1 0 2 2 0 9 9 0 , / N 6 6 2 0 0 0 5 8 2 1 , S / N 9 3 7 0 0 0 7 6 6 1 , / N 9 3 2 0 0 0 6 2 3 1 , S / N 9 4 7 0 0 0 6 0 8 0 , a n d / N 9 4 2 0 0 0 7 5 6 0 , m a t e r ia l o f s p e c ifi c e a ls h a s b e e n m o d i fi e d t o b e c o m p a t i b l e i t h D E X R O N ® - V I fl u i d s . T r a n s m i s s i o n s r i o r t o t h e a b o v e s e r i a l n u m b e r s a r e n o t o m p a t i b l e w i t h D E X R O N ® - V I fl u i d s . S e a l o m p a t ib i l i t y c a n b e id e n t ifi e d b y a " D 6 C " o r c o lo r m a r k s o n t h e f a c e o f t h e s e a l. S e e I L 6 - W T - 0 7 f o r m o r e in f o r m a t io n .

d .

o v e b u t t - jo i n t s ID ) . I f r e p la c e m d it i o n o f 9 0 m m 3 – 5 e . I n s p e c t in m e e t s e r v ic e s p th e P T O g e a r

e a l r in e n t is ID b e g B e a e c ifi c (1 2 ) u

A s s e m b ly o f th e P T O 1 . If r e a n d J – 3 B u s

m o v e d (1 4 ) o 8 5 6 5 P h in g In

, p n to u m s ta

g s ( 1 0 ) a n d ( 1 6 ) ( 8 8 r e q u i r e d , i n s p e c t t h e a r in g s ( 1 1 ) a n d ( 1 4 ) r i n g s . I f b e a r i n g s d o a t io n , r e m o v e t h e m s in g a b e a r in g p u l le r .

G e a r A s s e m b ly .

r e s s 9 0 m m I D b e a r in g s ( 1 1 ) s h o u l d e r o f g e a r ( 1 2 ) , u s i n g p G e a r, T o r q u e C o n v e r t e r C o v e r l l e r .

2 . I n s t a l l 6 8 m m o i l p u m p d r iv e h u b ( 1 3 ) i n t o P T O g e a r ( 1 2 ) . I n s t a l l r e t a i n i n g r i n g ( 1 5 ) o n t o o i l p u m p d r iv e h u b ( 1 3 ) . 3 . R e f tw o s e a a n d

e r b lin m

to u ttg b e a

3 – 6 h . jo in t s e o re o f s u re th


B u tt-J a lr in g b e a r in e e n d

o in t S s (1 0 ) g re ta g a p w

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s . 6 ) u s le r

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r t t h e ( 7 ) g e s . 5 - 7


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M a x im u m a l l o w a b l e s e a lr i n g e n d g a p f o r r e u s e is 1 .1 5 m m ( 0 .0 4 5 in c h ) — 0 . 5 7 m m ( 0 . 0 2 2 i n c h ) . 4 . R e m (1 6 ) h o u s (1 2 ) in s ta g e a r e .

o v e th e (8 8 m m in g a n d if t h e y m ll n e w b ( 1 2 ) .

tw o b u ID ) fro in s ta ll e e t s p u t t - jo i n

t t - jo i n t s e a m th e b e a th e m o n to e c ifi c a t io n t s e a lr in g s

h o u s i n g ( 2 2 ) . T i g h t e n t h e b o l t s t o 5 1 – 6 1 N ∙ m ( 3 8 – 4 5 l b f t ) . 4 . If u s e (2 4 ) u e a c h (3 8 – 4

l r i n g s ( 1 0 ) a n d r in g r e t a i n e r t h e P T O g e a r . O t h e r w is e , o n t h e P T O

5 – 5 . O T E : B e g i n n i n g w i t h S / N 6 5 1 0 7 1 7 2 8 1 , / N 6 5 2 0 0 8 3 0 9 3 , S / N 6 6 1 0 2 2 0 9 9 0 , / N 6 6 2 0 0 0 5 8 2 1 , S / N 9 3 7 0 0 0 7 6 6 1 , / N 9 3 2 0 0 0 6 2 3 1 , S / N 9 4 7 0 0 0 6 0 8 0 , a n d / N 9 4 2 0 0 0 7 5 6 0 , m a t e r ia l o f s p e c ifi c e a ls h a s b e e n m o d i fi e d t o b e c o m p a t i b l e i t h D E X R O N ® - V I fl u i d s . T r a n s m i s s i o n s r i o r t o t h e a b o v e s e r ia l n u m b e r s a r e n o t o m p a t i b l e w i t h D E X R O N ® - V I fl u i d s . S e a l o m p a t ib i l i t y c a n b e id e n t ifi e d b y a " D 6 C " o r c o lo r m a r k s o n t h e f a c e o f t h e s e a l. S e e I L 6 - W T - 0 7 f o r m o r e in f o r m a t io n .

1 . If r e m o v e d , in s ta ll in c h e s ) u s in g a p r J – 3 5 9 2 2 -2 O il P u m S le e v e B e a r in g /P 1 a n d J – 8 0 9 2 D r iv e (6 ) fl u s h to 0 .2 5 m s u r f a c e .

b u e s p S H m

s h in g ( 6 ) 7 s o r s o ft m B o d y B u s u n G e a r B a n d le . P r e ( 0 .0 1 0 in c

5 .5 m m a lle t a h in g / G u s h in g s s b u s h ) b e lo

a .

2 . U s e g u i d e b o l t s t o i n s t a l l b e a r i n g r e t a i n e r a s s e m b l y ( 3 ) , r o c k i n g t h e r e t a i n e r w h i l e i n s t a l l i n g .

D i s a s s e m b l y ( F o l d o u t 6 - 1 ) .

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IN S P E C T IO N

v e d , r e m o v e in g b o lt ( 6 ) M 8 x r a c k e t ( 5 ) , in p u a n d O - r in g ( 4 ) . s s e m b ly ( F o ld o

p u t 1 . 2 5 x t s p e e d R e f e r u t 6 - 2 ) ,

2 . R e m o v e b r e a t h e r a s s e m b ly ( 9 ) u s in g a t h in 1 4 m m w r e n c h . A s s e m b l y ( F o l d o u t 6 - 1 ) . 1 . B 2 a in 2

e s 0 is s s e s ta 4 – 2

u re O -r in p la c m b ly ( 3 ll r e t a in 9 N ∙m

in g ( 4 ) , ID e a n d in s ) . H o ld b in g b o lt ( ( 1 8 – 2 1 lb

1 5 .6 ta ll in p ra c k e t 6 ) . T ig f t ) .

m m , M 8 u t s p e e d ( 5 ) in p la h te n th e

x 1 .2 s e n c e a b o lt

5 x s o r n d t o

2 . I n s t a l l b r e a t h e r ( 9 ) . T i g h t e n t h e b r e a t h e r t o 1 2 – 1 6 N ∙ m ( 9 – 1 2 lb f t ) .

3 . I n s t a ll t e n M 1 0 x 1 . 5 x 3 5 b o l t s ( 2 ) h o l d in g b e a r i n g t h e r e t a i n e r a s s e m b l y ( 3 ) i n t o t h e 5 - 8

A N D

1 . I f n o t p r e v io u s ly r e m o s p e e d s e n s o r r e ta in in 2 0 , s e n s o r re ta in in g b s e n s o r a s s e m b ly ( 3 ) , to 5 – 4 a . M o d u le D is a S t e p 1 .

b .

1 . W it h a m a l le t , l ig h t ly t a p P T O g e a r a s s e m b l y ( 9 ) i n t o c o n v e r t e r h o u s i n g ( 2 2 ) u n t i l t h e g e a r a s s e m b l y is s e a t e d .

T O R Q U E C O N V E R T E R H O U S I N G M O D U L E ( M o d e ls W it h o u t P T O P r o v i s i o n )

N O T E : B e g i n n i n g J a n u a r y 2 0 0 6 a n d w i t h S / N 6 5 1 0 6 3 0 0 8 9 a n d S /N 5 2 0 0 5 7 8 2 0 , a ll s p e e d s e n s o r s w e r e r e d e s ig n e d . S e e F i g u r e 3 – 7 t o i d e n t i f y f o r m e r o r c u r r e n t s p e e d s e n s o r t y p e s . S e e T a b le 3 – 2 f o r a l l s p e e d s e n s o r s p e c i fi c a t io n s o f f o r m e r a n d c u r r e n t t y p e . S e e T S 3 9 8 9 f o r D T C , c o n n e c t o r , a n d c i r c u i t i n f o r m a t i o n . I n f o r m a t i o n a b o u t t h i s c h a n g e m a y a l s o b e f o u n d i n S I L 5 - W T - 0 6 .

( 2 . 9 7 2 n d r o u n d I n s t a l le r h in g w t h e

M o d u le A s s e m b ly .

l l P T O c o v e r ( s ) ( 2 5 ) a n d g a s k e t ( s ) n M 1 0 x 1 . 5 x 2 5 b o lt s ( 2 6 ) i n T i g h t e n t h e b o l t s t o 5 1 – 6 1 N ∙ m .

R e fe r to 3 – 5 . C L E A N I N G

2 . I n s t a l l s e a l r i n g ( 8 ) ( 1 7 8 . 8 m m ) . I n s t a l l o i l s e a l ( 4 ) fl u s h t o 0 . 2 5 m m ( 0 . 0 1 0 in c h ) b e l o w t h e s u r f a c e u s in g a p r e s s a n d J – 3 5 9 2 1 - 3 O il P u m p ( I n p u t ) S e a l I n s t a l l e r a n d J – 3 5 9 2 1 - 1 O u t p u t B e a r i n g I n s t a l l e r / D r i v e S l e e v e . P r e s s s e a l r i n g ( 8 ) fl u s h , t o 0 . 2 5 m m ( 0 . 0 1 0 in c h ) b e l o w t h e s u r f a c e . f.

ta te r. ft)

5 . I n s t a l l b r e a t h e r ( 2 8 ) o r b r e a t h e r a d a p t e r ( 2 9 ) . T i g h t e n t h e b r e a t h e r o r b r e a t h e r a d a p t e r t o 1 2 – 1 6 N ∙ m ( 9 – 1 2 l b f t ) u s in g a t h in 1 4 m m w r e n c h .

A s s e m b l y o f t h e B e a r i n g R e t a in e r A s s e m b l y .


d , in s s in g c o v e 5 lb


M O D U L E 5 – 6 .

a .

R E B U IL D

F R O N T S U P P O R T A N D C H A R G IN G O IL P U M P M O D U L E

M o d u l e D i s a s s e m b l y ( F o l d o u t 7 - 1 ) . 1 . R e m o v e th re e 8 8 m m f r o n t s u p p o r t h u b . 2 . R e m o v e 1 0 4 m m

ID

ID

s e a ls ( 2 3 ) f r o m

t h e

th r u s t b e a r in g ( 2 4 ) .

3 . R e m o v e e ig h t M 1 0 x 1 . 5 x 6 5 b o lt s ( 6 ) t h a t r e t a i n p u m p h o u s i n g a s s e m b l y ( 7 ) t o f r o n t s u p p o r t a s s e m b l y ( 1 5 ) . 4 . R e m o v e p u m p h o u s i n g a s s e m b ly ( 7 ) ( F ig u r e 5 – 1 2 ) a n d g e a r s e t ( 1 0 ) .

F i g u r e 5 – 1 3 . M a i n P r e s s u r e R e l i e f S p r i n g C o m p r e s s o r A t t a c h m e n t

F i g u r e 5 – 1 2 . P u m p H o u s in g A s s e m b l y 5 . C J C ( o (

o m – 4 1 o m F ig u n th 2 7 )

p re s s p re s 4 6 2 M a in p re s s o r (F re 5 – 1 5 ). e s p r in g a ( F ig u r e 5 –

s u re P re s ig u re S lo w n d re 1 6 ) .

re s u 5 ly m

lie re – 1 re o v

f s p r i n g ( 2 6 ) u s i n g R e lie f S p r in g 4 ) . R e m o v e p in ( 2 5 ) l e a s e t h e p r e s s u r e e s p r in g ( 2 6 ) a n d b a ll

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2 0 0 9

F i g u r e 5 – 1 4 . C o m p r e s s P r e s s u r e R e l i e f S p r i n g


5 - 9

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F ig u r e 5 – 1 5 . P in

R e m o v a l

F i g u r e 5 – 1 7 . M e a s u r i n g G e a r - C a v i t y D e p t h In T h e P u m p H o u s in g 8 . M e a s u r e g e a r - c a v it y d ia m e t e r in t h e p u m p h o u s i n g ( F i g u r e 5 – 1 8 ) . M a x i m u m a l l o w a b l e I D f o r r e u s e is 1 2 7 . 3 0 m m ( 5 . 0 1 2 in c h ) .

F i g u r e 5 – 1 6 . P u m p H o u s in g S p r i n g a n d B a ll 6 . O n m o d e l s w i t h o u t P T O , r e m o v e 4 – in c h I D O - r in g ( 4 ) . R e m o v e o il s e a l ( 5 ) u s in g J – 2 4 1 7 1 - A S lid e H a m m e r a n d J a w S e t. 7 . M e a s u r e g e a r - c a v it y d e p t h in t h e p u m p h o u s in g ( F ig u r e 5 – 1 7 ) . M a x i m u m a l l o w a b l e d e p t h f o r r e u s e is 1 7 . 9 3 m m ( 0 . 7 0 6 in c h ) .

F i g u r e 5 – 1 8 . M e a s u r i n g G e a r - C a v i t y D i a m e t e r In T h e P u m p H o u s in g 9 . O n n o ( 8 ) in s w e a r o b u s h in 7 5 .1 5 re m o v

n -P id e r d g . m m e b

T O m o p u m p a m a g e M a x im (2 .9 5 u s h in g

d e ls h o u s . M e u m a in c h (8 ) f

o n ly , in g ( 9 a s u re llo w a ). If w ro m p

in s p e c t b u s h ) ( F o ld o u t 7 th e ID o f th e b le ID fo r r e u o rn o r d a m a u m p h o u s in g

in g 1 ) f o r p u m p s e is g e d , ( 9 ) .

1 0 . If p u m p h o u s in g ( 9 ) i s w o r n o r d a m a g e d , r e p la c e t h e p u m p h o u s in g . 5 - 1 0

C o p y r ig h t ©


M O D U L E

R E B U IL D

1 1 . M e a s u r e t h e O D o f t h e d r iv e n ( o u t e r ) p u m p g e a r . M in im u m a llo w a b le O D is 1 2 6 . 9 5 m m ( 4 . 9 9 8 i n c h ) . 1 2 . M e a s u r e t h e w id t h o f t h e d r iv e n p u m p g e a r . M in i m u m a l lo w a b l e w id t h f o r r e u s e is 1 7 . 8 1 m m ( 0 .7 0 1 in c h ) . 1 3 . In s g e th e ID o r th e

p e c t th a r fo r w d r iv e fo r re u d a m a g d r iv e

e b u s h in g in s id e a r o r d a m a g e g e a r b u s h in g . M s e is 5 7 . 3 0 m m e d , re m o v e th e g e a r .

e th e . M e a a x im (2 .2 5 b u s h

d r i v e ( i n n e r ) s u r e t h e I D o f u m a l lo w a b l e 6 in c h ) . I f w o r n in g ( 1 1 ) f r o m

1 4 . M e a s u r e t h e w id t h o f t h e d r iv e a n d d r iv e n p u m p g e a r s . M in im u m a llo w a b le w id t h f o r r e u s e is 1 7 . 8 1 m m ( 0 . 7 0 1 in c h ) . 1 5 . E x a m i n e t h e t a n g s lo t s i n t h e d r i v e p u m p g e a r . R e p l a c e t h e g e a r if t h e s lo t s h a v e s t e p w e a r . 1 6 . In (9 (F fo

s ta ll g ). M e ig u r e r re u s

e a r a s u 5 – 1 e is

s e t ( re p u 9 ). M 0 .1 3

1 0 ) m p a x im m m

in t o p u m g e a r s id u m a llo (0 .0 0 5

p h o u s in g e c le a r a n c e w a b l e c l e a r a n c e in c h ) .

F i g u r e 5 – 1 9 . M e a s u r i n g G e a r S i d e C l e a r a n c e In T h e P u m p H o u s in g 1 7 . M e a s u r e g e a r t o o t h t i p c le a r a n c e ( F i g u r e 5 – 2 0 ) . M a x im u m a l lo w a b l e c le a r a n c e f o r r e u s e is 0 . 2 0 m m ( 0 . 0 0 8 in c h ) .

F i g u r e 5 – 2 0 . M e a s u r i n g G e a r T o o t h T i p C l e a r a n c e I n T h e P u m p H o u s in g 1 8 . M e a s u ( d ia m e M a x im 0 .3 6 m

r e d r iv e n tr ic a l) c le u m a llo w m (0 .0 1 4

F i g u r e 5 – 2 1 . M e a s u r i n g D r i v e n G e a r C l e a r a n c e In T h e P u m p H o u s in g 1 9 . I f a n y m e a s u r e m e n t is o u t o f s p e c ifi c a t io n , r e p l a c e t h e p u m p h o u s in g a n d / o r g e a r s e t ( 1 0 ) a n d r e p e a t S t e p s 1 1 t h r o u g h 1 8 . 2 0 . R e m o v e te n ( F o ld o u t 7 - 1 ) p r e s e n t, a n d s u p p o rt a s s e

C o p y r ig h t ©

2 0 0 9

g e a r - t o - p u m p h o u s in g a r a n c e ( F i g u r e 5 – 2 1 ) . a b l e c le a r a n c e f o r r e u s e is in c h ) .


M 1 0 re ta w e a m b ly

x 1 in in g r p la (1 5

.5 x 2 s t iffe te (1 4 ). R e

5 b o lts ( 1 2 n in g p la te ) a tta c h e d m o v e s tiff e

) ( 1 3 ) , i f t o f r o n t n in g 5 - 1 1

S E R V IC E

p la te In s p e a n d d w e a r th ic k n


( 1 3 ) , if p r e s e n t , c t w e a r p la te ( 1 4 is to r t io n . M e a s u p la t e . M in im u m e s s fo r r e u s e is

C A U T I O N : B e le n g th b o lts w h o r t r a n s m is s io n b o lts ( 1 2 ) u s e d p re s e n t a re 5 m x 1 .5 x 3 0 ) th a s t iff e n in g p la te 2 1 . In s p e c t a s s e m b g u id e lin re m o v e H a m m e

6 3 m m O ly ( 1 5 ) . e s in 3 – b e a r in g r a n d J a

a n d w e a r p ) fo r s u rfa c r e th e th ic k a llo w a b le w 4 .7 0 m m (0

la te e d a n e s s e a r .1 8 5

(1 4 m a o f p la in c

) . g e t h e t e h ) .

s u r e t o u s e t h e c o r r e c t e n i n s t a l l i n g t h e f r o n t s u p p o r t d a m a g e w i l l o c c u r . T h e t e n w h e n t h e s t i f f e n i n g p l a t e i s m ( 0 . 1 9 7 in c h ) l o n g e r , ( M 1 0 n t h e b o lt s u s e d w h e n t h e i s n o t p r e s e n t . D b e a r in g ( 2 2 I f b e a r in g ( 2 2 ) 5 e . I n s p e c t in g w it h J – 2 4 1 7 1 w S e t.

) in d o B -A

f r o n t s u p p o r t e s n o t m e e t e a r i n g s , S lid e

2 2 . M e a s u r e t h e O D o f f r o n t s u p p o r t s le e v e ( 2 0 ) . M i n im u m a ll o w a b le O D i s 9 8 . 8 3 m m ( 3 . 8 9 1 i n c h ) . I f d a m a g e d , r e p l a c e f r o n t s u p p o r t ( 2 1 ) .

b .

A s s e m b l y o f t h e F r o n t S u p p o r t . N g b g

e O D o f 4 ) a t th e s h i n g . M .0 4 m m r w o rn b g ro u n d

g r o u n d s le e v e ( 1 6 ) o r ( 1 7 ) jo u r n a l f o r t h e o i l p u m p i n i m u m a l l o w a b l e O D f o r ( 2 . 2 4 6 i n c h ) . I f j o u r n a l i s e y o n d s e r v ic e l i m i t s t h e n s le e v e .

2 5 . I f w o r n o r d a m a g e d , r e m o v e g r o u n d s le e v e ( 1 6 ) o r ( 1 7 ) b y p r e s s i n g g r o u n d s l e e v e f r o m f r o n t s u p p o r t ( 2 1 ) . N O T E : 6 3 m m O D b e a r i n g ( 2 2 ) m u s t b e r e m o v e d w h e n r e m o v i n g g r o u n d s l e e v e ( 1 6 ) o r ( 1 7 ) f r o m f r o n t s u p p o r t ( 2 1 ) .

N O s u p th e s le e

5 - 1 2

T E p o s u v e

E : T o n d s le t ro o m n d s le

a v e v te e v

f r o n t s u p p o r t d i s t o r t i o n , t h e n d f r o n t s u p p o r t m u s t b o t h e r a t u r e w h i le p r e s s in g t h e t h e f r o n t s u p p o r t .

2 . I f r e m o v e d , i n s t a l l d o w e l p i n ( s ) ( 1 9 ) . P r e s s t h e p i n ( s ) t o a h e i g h t o f 1 4 . 5 m m ( 0 . 5 7 in c h ) f r o m t h e s u r f a c e ( F ig u r e 5 – 2 4 , V ie w A ) . C A U T I O N : B e le n g t h b o lt s w h o r t r a n s m is s io n b o lt s ( 1 2 ) u s e d p re s e n t a re 5 m x 1 .5 x 3 0 ) th a s t iffe n in g p la te 3 . In s ta w e a r M 1 0 5 1 – 6 4 . In p B B P in

ll s t iff e n in g p la te (1 4 ) x 1 .5 x 2 5 1 N ∙m (3 8

s t a ll re s s u s h in u s h in re s s c h ) b

s u r e t o u s e t h e c o r r e c e n in s t a l lin g t h e fr o n t s u d a m a g e w ill o c c u r . T h w h e n th e s tiffe n in g p la m ( 0 .1 9 7 in c h ) lo n g e r n t h e b o lt s u s e d w h e n i s n o t p r e s e n t .

p la te (F o ld b o lts – 4 5 lb


t p p o r t e t e n t e i s ( M 1 0 t h e

( 1 3 ) , i f p r e s e n t , a n d o u t 7 - 1 ) . S e c u r e w i t h t e n ( 1 2 ) . T i g h t e n t h e b o l t s t o f t ) .

6 3 m m O D b e a r in g ( 2 2 ) a n d J – 3 5 9 2 2 - 2 O il P u m p g / G r o u n d S le e v e B e a r in g g In s t a lle r a n d J – 8 0 9 2 D b e a r in g ( 2 2 ) fl u s h t o 0 . 2 5 e lo w t h e s u r f a c e .

: T o k e e p f r o m d i s t o r t i n g f r o n t r t , d o n o t u s e b lo c k s t o s p a c e u p p p o r t w h i le p r e s s in g a n e w g r o u n d .

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o id e a m p e in

1 . I f r e m o v e d , i n s t a l l g r o u n d s le e v e ( 1 6 ) o r ( 1 7 ) ( F o l d o u t 7 - 1 a n d F ig u r e 5 – 2 4 ) . P l a c e f r o n t s u p p o r t ( 2 1 ) o n p r e s s b e d w it h f r o n t s u p p o r t r e s t i n g o n h u b . T h e m a c h in e d fl a t a t t h e b a s e o f t h e g r o u n d s le e v e m u s t a l ig n w it h t h e c a s t a r r o w o n t h e f r o n t s u p p o r t ( F i g u r e 5 – 2 4 , V i e w C ) . P r e s s g r o u n d s le e v e ( 1 6 ) o r ( 1 7 ) in t o f r o n t s u p p o r t ( 2 1 ) t o t h e s h o u l d e r . A f t e r i n s t a l l a t i o n , t o t a l r u n o u t m a y n o t e x c e e d 0 . 3 0 m m ( 0 . 0 1 2 in c h ) S e e ( F i g u r e 5 – 2 4 , V ie w A ) .

2 3 . I f d a m a g e d , r e m o v e d o w e l p i n ( s ) ( 1 9 ) f r o m f r o n t s u p p o r t ( 2 1 ) . 2 4 . M e a s u re th ( F ig u r e 5 – 2 g e a r s e t b u r e u s e is 5 7 d a m a g e d o re p la c e th e

O T ro u e a ro u

u s B /P r iv m

in g a o d y 1 S u n G e a r e H a n d l e . m ( 0 . 0 1 0

M O D U L E c .

R E B U IL D

A s s e m b l y o f t h e P u m p H o u s i n g ( F o l d o u t 7 - 1 ) .


O T E : B e g i n n i n g w i t h S / N 6 5 1 0 7 1 7 2 8 1 , / N 6 5 2 0 0 8 3 0 9 3 , S / N 6 6 1 0 2 2 0 9 9 0 , / N 6 6 2 0 0 0 5 8 2 1 , S / N 9 3 7 0 0 0 7 6 6 1 , / N 9 3 2 0 0 0 6 2 3 1 , S / N 9 4 7 0 0 0 6 0 8 0 , a n d / N 9 4 2 0 0 0 7 5 6 0 , m a t e r ia l o f s p e c ifi c e a ls h a s b e e n m o d i fi e d t o b e c o m p a t ib l e i t h D E X R O N ® - V I fl u i d s . T r a n s m i s s i o n s r io r t o t h e a b o v e s e r ia l n u m b e r s a r e n o t o m p a t i b l e w i t h D E X R O N ® - V I fl u i d s . S e a l o m p a t i b i l i t y c a n b e i d e n t i fi e d b y a " D 6 C " o r c o lo r m a r k s o n t h e f a c e o f t h e s e a l. S e e I L 6 - W T - 0 7 f o r m o r e in f o r m a t io n .

F i g u r e 5 – 2 2 . P u m p H o u s in g S p r i n g a n d B a ll

N O T E : • F o r m o d e ls w i t h o u t P T O , p r o c e e d w it h S t e p 1 . • F o r m o d e ls w it h P T O , s k ip t o S t e p 4 . 1 . If o ld b u s h in g w a s b u s h in g ( 8 ) 7 5 . 1 5 p u m p h o u s in g ( 9 ) J – 3 5 9 2 2 - 2 O il P u m S le e v e B e a r in g / P 1 a n d J – 8 0 9 2 D r iv e 2 . In s ta J – 3 5 a n d S le e

re m m m u s in p B S u n H a n

o v e d , in I D ( F o ld g a p re s o d y B u s G e a r B d le .

s ta o u t s a h in u s h

l l n e w 7 - 1 ) in t o n d t o o ls g / G r o u n d i n g I n s t a l l e r

l l o il s e a l ( 5 ) u s i n g a p r e s s a n d 9 2 1 - 3 O il P u m p ( I n p u t ) S e a l I n s t a l le r J – 3 5 9 2 1 - 1 O u t p u t B e a r i n g I n s t a l l e r / D r i v e v e .

3 . I n s t a ll a 4 . 4 in c h I D 4 . In s ta ll p re s s u r e r r e lie f s p r in g ( 2 6 ) (F ig u r e 5 – 2 2 ) . U P r e s s u r e R e lie f S s p r in g ( 2 6 ) . In s t a b a ll ( F ig u r e 5 – 2 3

O - r in g ( 4 ) .

e l ie f b a ll ( in t o p u m s in g t o o l p r in g C o m ll p in ( 2 5 ) ) .

2 7 ) a n d p r e s s u r e p h o u s i n g J – 4 1 4 6 2 M a in p r e s s o r , c o m p r e s s t o r e t a i n s p r i n g a n d

C o p y r ig h t ©

2 0 0 9

F i g u r e 5 – 2 3 . C o m p r e s s P r e s s u r e R e l i e f S p r i n g


5 - 1 3

S E R V IC E


F ig u re 5 – 2 4 . G ro u n d

S le e v e R e m o v a l a n d

I n s t a l l a t i o n

5 . L u b r ic a te p u m p g e a r s e t ( 1 0 ) t o p r e v e n t d a m a g e a n d in s ta ll t h e g e a r s e t in p u m p h o u s i n g ( 9 ) . 6 . A u 1 N

tta s in .5 ∙m

c h th g th e x 6 5 (3 8 –

7 . In s ta s u p p th r u s b e a r 3 – 5 e

5 - 1 4

ll o t in .

e p u m tw o b o lts 4 5 lb

p h o u s in g t o t h e f r o n t s u p p o r t lo c a t in g p i n s , w it h e i g h t M 1 0 x ( 6 ) . T i g h t e n t h e b o l t s t o 5 1 – 6 1 f t ) .

1 0 4 m m ID r t ( 2 1 ) ( F ig u b e a r in g s , ta g c o n s is te n I n s p e c t in g

t h r u s t b e a r in re 5 – 2 5 ). W k e c a re to o t to F ig u r e 3 B e a r in g s .

g ( 2 4 ) o n t o f r o n t h e n i n s t a l l i n g r i e n t t h e t h r u s t – 4 s h o w n in

C o p y r ig h t ©


M O D U L E

R E B U IL D 3 . In s p e c b u s h in re u s e b u s h in d a m a g

t a n d g (4 3 ) is 6 8 .2 g w ith e d o r

m e a s u re th . M a x im u m 2 m m (2 .6 8 a h a m m e r w o rn b e y o n

4 . R e m o v e 2 9 8 m m

ID

e I D o f s u n g e a r a l lo w a b l e I D f o r 5 in c h ) . R e m o v e t h e a n d c h i s e l i f v i s u a l l y d s e r v ic e lim it s .

r e t a in in g r in g ( 4 4 ) .

5 . R e m o v e C 2 c lu t c h p r e s s u r e p la t e ( 3 9 ) . 6 . M p r o a (

e a s la te e u s e f th e llo w 0 .0 1

u r e t h e t h ic k n e s s o f C 2 c lu t c h p r e ( 3 9 ) . M in im u m a llo w a b le t h ic k n e s is 6 . 2 5 m m ( 0 . 2 4 6 in c h ) . C h e c k fl C 2 c lu t c h p r e s s u r e p l a t e ( 3 9 ) . M a a b le d is to r tio n fo r r e u s e is 0 . 4 5 m 8 i n c h ) .

s s u r e s f o r a t n e s s x i m u m m

7 . R e m o v e s ix C 2 c lu t c h p a c k f r ic t io n p l a t e s ( 3 8 ) a n d s i x s t e e l r e a c t i o n p l a t e s ( 3 7 ) . F i g u r e 5 – 2 5 . T h r u s t B e a r i n g I n s t a l l e d o n F r o n t S u p p o r t 8 . In s e in t o a n d M a x re u s

rt th m im e

th re e s e e a s u m is 0

e 8 8 a l in g u re th a llo w .5 7 m

9 . R e m o v e th r e e t h e r o t a t in g c lu th e h u b o f fro n m e e t s p e c ifi c a s e a l r i n g s .

5 – 7 . a .

m m ID b o re o e e n d a b le s m (0 .0

b u t t - jo i n t s e a l r in f th e r o t a t in g c lu g a p w ith f e e le r g e a lr i n g e n d g a p 2 2 in c h ) .

b u t t - jo i n t s tc h h u b a n t s u p p o r t ( t io n s , r e p la

R O T A T IN G

e a d 2 1 c e

lr in g in s t a ) . If a ll t

C L U T C H

g s ( 2 3 ) t c h h u b a u g e s . f o r

s ( 2 3 ) f r o m l l t h e m o n t o a n y d o n o t h r e e b u t t - j o i n t

M O D U L E

D i s a s s e m b l y ( F o l d o u t 7 - 2 ) . N S N S N h D p c c 8 S

O T E : B e g i n n i n g w i t h S / N 6 5 1 0 7 1 7 2 8 1 , / N 6 5 2 0 0 8 3 0 9 3 , S / N 6 6 1 0 2 2 0 9 9 0 , S / 6 6 2 0 0 0 5 8 2 1 , S / N 9 3 7 0 0 0 7 6 6 1 , / N 9 3 2 0 0 0 6 2 3 1 , S / N 9 4 7 0 0 0 6 0 8 0 , S / 9 4 2 0 0 0 7 5 6 0 , m a t e r ia l o f s p e c ifi c s e a l s a s b e e n m o d ifi e d t o b e c o m p a t ib le w it h E X R O N ® - V I fl u i d s . T r a n s m i s s i o n s r io r t o t h e a b o v e s e r ia l n u m b e r s a r e n o t o m p a t i b l e w i t h D E X R O N ® - V I fl u i d s . S e a l o m p a t i b i l i t y c a n b e i d e n t i fi e d b y a " D 6 C " o r c o lo r m a r k s o n t h e f a c e o f t h e s e a l. S e e I L 6 - W T - 0 7 f o r m o r e in f o r m a t io n .

1 . R e m o v e 2 9 8 m m

ID

r e ta in in g r in g ( 4 0 ) .

2 . R e m o v e P 1 s u n g e a r a s s e m b ly ( 4 1 ) . C o p y r ig h t ©

2 0 0 9

8 . V i s u a l l y i n s p e c t e a c h f r i c t i o n p l a t e f o r d a m a g e o r e x c e s s i v e w e a r . I f a n y p l a t e h a s p e r c e i v a b l e w e a r o r d i s t o r t io n , m e a s u r e t h e t h i c k n e s s o f e a c h f r i c t i o n p l a t e ( 3 8 ) . M i n i m u m a l l o w a b l e t h i c k n e s s f o r r e u s e is 2 . 2 1 m m ( 0 . 0 8 7 in c h ) . M e a s u r e t h e o il g r o o v e d e p t h a n d c o n e o f e a c h f r i c t i o n p l a t e . M i n i m u m a l l o w a b l e g r o o v e d e p t h f o r r e u s e is 0 . 2 0 m m ( 0 . 0 0 8 in c h ) . M a x im u m a l lo w a b l e c o n e f o r r e u s e is 0 . 4 0 m m ( 0 . 0 1 6 in c h ) . 9 . V is u a l ly in d a m a g e o p e rc e iv a b th ic k n e s s p la te (3 7 ) r e u s e is 2 a llo w a b le i n c h ) .

s p e c t e a c h s t e e l r e a c t i o n p l a t e f o r r e x c e s s iv e w e a r . I f a n y p la t e h a s l e w e a r o r d i s t o r t i o n , m e a s u r e t h e a n d c o n e o f e a c h s t e e l r e a c t i o n . M i n i m u m a l l o w a b l e t h i c k n e s s f o r . 3 6 m m ( 0 . 0 9 3 in c h ) . M a x im u m c o n e f o r r e u s e is 0 . 4 0 m m ( 0 . 0 1 6

1 0 . R e m o v e C 2 d r i v e h u b ( 3 6 ) , i n c lu d i n g t w m m ID th r u s t b e a r in g s ( 3 5 ) . I n s p e c t t h b e a r in g s ( 3 5 ) u s in g g u id e lin e s fr o m 3 – In s p e c tin g B e a r in g s . R e p l a c e a n y t h r u b e a r in g t h a t d o e s n o t m e e t s p e c ifi c a t io I n s p e c t t h e s p lin e s o f t h e C 2 d r iv e h u b M a x im u m a llo w a b le s p lin e w e a r f o r r e u 0 . 3 8 m m ( 0 . 0 1 5 in c h ) .

o 7 4 r u s t 5 e . s t n s . . s e is

1 1 . R e m o v e C 1 d r iv e h u b ( 3 4 ) . I n s p e c t t h e s p lin e s o f t h e C 1 d r iv e h u b . M a x im u m a llo w a b le s p lin e w e a r f o r r e u s e is 0 . 3 8 m m ( 0 . 0 1 5 in c h ) . 1 2 . R e m o v e 1 0 4 b a c k in g p l a t e s ix C 1 f r ic tio n r e a c t io n p la t e A ll is o n T r a n s m is s io n , I n c .

m m (3 2 p la s (3

ID

r e t a in in g r in g ( 3 3 ) , C 1 ) , s i x C 1 a p p l y p l a t e s ( 2 9 ) , t e s ( 3 0 ) , a n d fi v e s t e e l 1 ) . 5 - 1 5


S E R V IC E

1 3 . V is u a l ly in d a m a g e o p e rc e iv a b th ic k n e s s a llo w a b l e ( 0 . 0 8 7 in c a n d c o n e a llo w a b le ( 0 . 0 0 8 in c r e u s e is 0

s p e c t e a c h C 1 f r i c t i o n p l a t e ( 3 0 ) f o r r e x c e s s iv e w e a r . I f a n y p la t e h a s l e w e a r o r d i s t o r t i o n , m e a s u r e t h e o f e a c h f r i c t i o n p l a t e ( 3 0 ) . M i n i m u m t h i c k n e s s f o r r e u s e i s 2 . 2 1 m m h ) . M e a s u r e t h e o i l g r o o v e d e p t h o f e a c h f r ic t io n p l a t e . M in i m u m g r o o v e d e p t h f o r r e u s e is 0 . 2 0 m m h ) . M a x im u m a llo w a b l e c o n e f o r . 4 0 m m ( 0 . 0 1 6 in c h ) .

1 4 . V is u a l ly in s p e c t e fo r d a m a g e o r e x h a s p e r c e iv a b le w th e th ic k n e s s a n d p la t e ( 3 1 ) . M in im r e u s e is 2 .3 6 m m a llo w a b le c o n e fo i n c h ) . 1 5 . M e a s u re C 1 a p p ly th ic k n e s s C h e c k fl a a llo w a b le ( 0 .0 0 6 in c

a c h c e s e a c o u m (0 r re

th e w e a r p la t e ( 2 9 fo r re u s e tn e s s o f t d is to r tio n h ) .

s t e e l r e a c t i o n p l a t e ( 3 1 ) s iv e w e a r . I f a n y p la t e r o r d i s t o r t i o n , m e a s u r e n e o f e a c h s t e e l r e a c t io n a l l o w a b l e t h i c k n e s s f o r . 0 9 3 in c h ) . M a x im u m u s e is 0 . 4 0 m m ( 0 . 0 1 6 F i g u r e 5 – 2 6 . M e a s u r e W e a r S u r f a c e T h i c k n e s s

s u r fa c e th ic k n e s s ) . M in im u m a llo w is 4 . 2 0 m m ( 0 . 1 6 h e a p p l y p l a t e . M fo r r e u s e is 0 . 1 5

o f t h e a b l e 5 in c h ) . a x im u m m m

1 6 . M e a s u r e t h e w e a r s u r f a c e t h ic k n e s s o f t h e C 1 b a c k in g p l a t e ( 3 2 ) ( F ig u r e 5 – 2 6 ) . M in i m u m a l l o w a b l e t h i c k n e s s f o r r e u s e i s 8 . 2 0 m m ( 0 . 3 2 3 i n c h ) . C h e c k fl a t n e s s o f t h e b b a c k i n g p l a t e . M a x i m u m a l l o w a b l e d i s t o r t i o n f o r r e u s e is 0 . 1 5 m m ( 0 . 0 0 6 in c h ) . M e a s u r e w e a r f r o m t h e f r i c t i o n p l a t e s i d e t o t h e t o p o f t h e s p l i n e t o o t h ( F ig u r e 5 – 2 7 , F ig u r e 5 – 2 8 ) .

F ig u r e

5 - 1 6

C o p y r ig h t ©

5 – 2 7 . P r o p e r P l a c e m e n t o f M i c r o m e t e r – A


M O D U L E

R E B U IL D C 1 r e t u r n s p r in g a s s e m b ly ( 2 5 ) . R e m o v e r e t a i n i n g r i n g ( 2 8 ) . R e m o v e J 3 5 9 2 3 - 1 P i s t o n S p r in g C o m p r e s s o r ( C 1 ) . N S S S S s w p c c 8 S

F ig u r e 1 7 . R e m ro ta th r u 3 – 5

5 – 2 8 . P r o p e r P l a c e m e n t o f M i c r o m e t e r – B

o v e t in g s t b e e . In

7 4 m c lu t c h a r in g s p e c t

m

ID th h u b a s (1 5 ) u s in g B e a

r u s t b e a r in g ( 1 5 ) f r o m s e m b l y ( 1 2 ) . I n s p e c t i n g g u i d e l i n e s f r o m r in g s .

1 8 . R e m o v e 4 8 m m I D r e t a in in g r in g ( 1 6 ) f r o m t u r b i n e s h a f t a s s e m b l y ( 5 ) o r ( 8 ) . 1 9 . In s p e c t tu r b in e s h a ft b u s h e n d o f tu r b in e s h a ft ( 5 ) o r ID o f th e tu r b in e s h a ft b u s a llo w a b le I D f o r r e u s e is 2 in c h ) . R e m o v e w it h h a m m v i s u a l l y d a m a g e d o r w o r n l i m i t s .

in g (8 ) h in 0 .1 e r b e

( 7 ) i n s i d e t h e . M e a s u r e t h e g . M a x im u m 9 m m ( 0 . 7 9 5 a n d c h is e l if y o n d s e r v ic e

W A c o m d is a th e

R N p r s s s p

IN e s e m r in

2 2 . P la c e r o t a B a s e s o r t a n g s ( F ig J 3 5 9 2 3 -1 ( F ig u r e 5 – J 2 8 4 6 7 -3 C 1 b a la n c

G : P s e d . b ly . g fo rc

is to n B e e P e rs e is

t in g c lu o ta tin g u re 5 – P is to n 3 2 , V ie 4 H a n d e p is to

s p x tre o n a n o t

t u r b in e s h a ft

r in g s a m e ly c l in ju r y c o n tro

re a re c a lle d

t c h o n J 3 5 9 2 3 - 4 C o m p r e s s o r d r u m is s u p p o r t e d b y t o o l 3 2 , V ie w C ) . I n s t a l l S p r in g C o m p r e s s o r ( C 1 ) w A ) , b e a r i n g , w a s h e r , a n d l e . T i g h t e n t o o l , c o m p r e s s i n g n ( 2 6 ) ( F o l d o u t 7 - 2 ) a n d 2 0 0 9

2 4 . I n s ta ll J 3 5 9 2 3 – 4 C o m p r e s s o r B a s e , J 3 5 9 2 3 - 3 P is to n S p r in g C o m p r e s s o r ( C 2 ) a n d J 3 5 9 2 3 - 2 P is to n S p r in g C o m p r e s s o r ( C 5 ) ( F ig u r e 5 – 3 2 , V ie w B ) , b e a r in g , w a s h e r , a n d h a n d l e J 2 8 4 6 7 - 3 4 H a n d le . T ig h t e n t o o l a n d r e m o v e 2 9 8 m m I D r e t a in in g r in g ( 2 2 ) ( F o l d o u t 7 - 2 ) . R e m o v e t o o l s J 3 5 9 2 3 - 2 P is t o n S p r in g C o m p r e s s o r ( C 5 ) a n d J 3 5 9 2 3 - 3 P is to n S p r in g C o m p r e s s o r ( C 2 ) .

2 6 . R e m o v e a J 3 5 9 2 3 -4 re m o v e ro t o f th e a s s e th e r o t a t in g w e a r is 0 .3 N O re m in s d a m

h i g h l y f u l d u r in g n o c c u r i f .

C o p y r ig h t ©

2 3 . R e m o v e b a l a n c e p i s t o n ( 2 6 ) , ( w it h y e ll o w m a r k in g s ) s e a l r i n g ( 2 7 ) , a n d C 1 s p r i n g a s s e m b l y ( 2 5 ) .

2 5 . R e m o v e C 2 s p r i n g a s s e m b l y ( 2 1 ) .

2 0 . R e m o v e t h r e e 5 1 m m O D b u t t - jo in t s e a lr in g s ( 1 0 ) f r o m t u r b i n e s h a f t a s s e m b l y ( 5 ) o r ( 8 ) . 2 1 . R e m o v e O - r in g ( 4 ) f r o m a s s e m b l y ( 5 ) o r ( 8 ) .

O T E : B e g i n n i n g w i t h S / N 6 5 1 0 7 1 7 2 8 1 , / N 6 5 2 0 0 8 3 0 9 3 , S / N S / N 6 6 1 0 2 2 0 9 9 0 , / N 6 6 2 0 0 0 5 8 2 1 , S / N 9 3 7 0 0 0 7 6 6 1 , / N 9 3 2 0 0 0 6 2 3 1 , S / N 9 4 7 0 0 0 6 0 8 0 , a n d / N 9 4 2 0 0 0 7 5 6 0 , m a t e r ia l o f s p e c ifi c e a ls h a s b e e n m o d i fi e d t o b e c o m p a t i b l e i t h D e x r o n ® - V I fl u i d s . T r a n s m i s s i o n s r i o r t o t h e a b o v e s e r i a l n u m b e r s a r e n o t o m p a t i b l e w i t h D e x r o n ® - V V I fl u i d s . S e a a l o m p a t i b i l i t y c a n b e i d e n t i fi e d b y a " D 6 C " o r c o lo r m a r k s o n t h e f a c e o f t h e s e a l. S e e I L 6 - W T - 0 7 f o r m o r e in f o r m a t io n .

s s C a t m d 8

e m b o m p in g c b ly . ru m m m

ly f r o re s s o lu t c h In s p e . M a x (0 .0 1

m r B a s d ru m c t th e im u m 5 in c h

e . T (1 1 ) c lu t a llo ) .

h e fro c h w a

n m t h e r e s t s p l i n e s o f b l e s p l i n e

T E : D o n o t u s e p l i e r s o r v i s e g r i p s t o o v e o r d is a s s e m b le C 1 / C 2 a s s e m b ly t e p 2 7 a n d s t e p 3 0 . P a r t s m a y b e a g e d .

2 7 . R e m o a s a n b y ro c ( F ig u r

v e a s k in e 5

C 1 s e m g th – 2 9

a n d C 2 p is t o b ly f r o m h u b e p is to n s fro , F ig u r e 5 – 3 0


n s (2 a s s e m s id , a n d

0 ) a n m b ly e -to F ig u

d ( 2 4 ) ( 1 2 ) s i d e r e 5 – 3 1 ) .

5 - 1 7

S E R V IC E


F ig u r e 5 – 2 9 . P is to n

R e m o v a l A

F ig u r e 5 – 3 1 . P is to n 2 8 . In s p e c M a x im (3 .9 0 7 a s s e m A v o i d

F ig u r e 5 – 3 0 . P is to n

5 - 1 8

t ro u m in c b ly d a m

t a t in g a llo w h ). R (1 2 ) a g in

2 9 . R e m p is to lig h t ro ta t

o v e n s e b lu e in g c

3 0 . S e (2 0 R e m a (2 4 p is

ra te C 1 b y ta p p in o v e 1 7 9 s ) C 1 p is R e m o v e n ( 2 0 ) .

p a ) m rk ). to

1 1 6 m a lr in g m a r k lu t c h

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c lu t c h a b le b e m o v e if r e p la g th e b m

ID (1 7 ), s ) C 1 h u b a

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h u u s h th e c e m u s h

b b u s in g I D b u s h e n t is in g b o

h in g ( 1 3 ) is 9 9 .2 5 in g f r o m n e c e s s a r e .

( w ith a n d p is to s s e m

p in k 1 0 1 m n s e a b ly (1

m a rk s ) C 2 m I D ( w it h l r i n g ( 1 8 ) f r o m 2 ) .

p is to n ( 2 4 ) f r o m C 2 p is g lig h t ly o n th e C 1 p is to m m ( 7 .0 3 9 ) I D ( w it h o r a to n s e a lr in g ( 2 3 ) f r o m C C 2 p is to n s e a lr in g ( 1 9 )

to n n 1

. m m h u b r y .

n ( 2 4 ) . g e p i s t o n f r o m C 2

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2 0 0 9

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5 - 1 9


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b .

A s s e m b l y ( F o l d o u t 7 - 2 ) . N S S S S s w p c c 8 S 1 . If m h B B

O T E : B e g i n n i n g w i t h S / N 6 5 1 0 7 1 7 2 8 1 , / N 6 5 2 0 0 8 3 0 9 3 , S / N 6 6 1 0 2 2 0 9 9 0 , / N 6 6 2 0 0 0 5 8 2 1 , S / N 9 3 7 0 0 0 7 6 6 1 , / N 9 3 2 0 0 0 6 2 3 1 , S / N 9 4 7 0 0 0 6 0 8 0 , a n d / N 9 4 2 0 0 0 7 5 6 0 , m a t e r ia l o f s p e c ifi c e a ls h a s b e e n m o d i fi e d t o b e c o m p a t i b l e i t h D e x r o n ® - V I fl u i d s . T r a n s m i s s i o n s r i o r t o t h e a b o v e s e r ia l n u m b e r s a r e n o t o m p a t i b l e w i t h D e x r o n ® - V I fl u i d s . S e a l o m p a t ib i l i t y c a n b e id e n t ifi e d b y a " D 6 C " o r c o lo r m a r k s o n t h e f a c e o f t h e s e a l. S e e I L 6 - W T - 0 7 f o r m o r e in f o r m a t io n .

re m o m ID u b (1 u s h in u s h in

v e d d u r in g b u s h in g (1 4 ) u s in g J 3 g /G ro u n d S g I n s ta lle r a

N O T E th e b u th e b u b u s h in b o re o b e lo w


h u b a s s e m b l y ( 1 4 ) . L i g h t l y t a p u n t i l i t i s f u l l y s e a t e d .

: F o s h in s h in g m r n o th e

d is 3 ) 5 9 le e n d

a s s e in t o 2 2 -2 v e B J 8 0

r a ll fl u s h m g w it h its b g u n til it s e u s t b e fl u s m o re th a n b o r e t o p .

o u o re a ts h w 0 .2

m b ly , in s t a r o t a t in g c lu O il P u m p e a r in g / P 1 9 2 D r iv e H

l l 9 9 . 1 5 t c h B o d y S u n G e a r a n d le .

n t b u s a n d p . T h e ith th e 5 m m

s ; a l i g n o r d r i v e o f t h e o f t h e 1 0 in c h )

h in g re s s to p to p (0 .0

O T E : B e g i n n i n g w i t h S / N 6 5 1 0 7 1 7 2 8 1 , / N 6 5 2 0 0 8 3 0 9 3 , S / N 6 6 1 0 2 2 0 9 9 0 , / N 6 6 2 0 0 0 5 8 2 1 , S / N 9 3 7 0 0 0 7 6 6 1 , / N 9 3 2 0 0 0 6 2 3 1 , S / N 9 4 7 0 0 0 6 0 8 0 , / N 9 4 2 0 0 0 7 5 6 0 , m a t e r ia l o f s p e c ifi c e a ls h a s b e e n m o d i fi e d t o b e c o m p a t i b l e i t h D e x r o n ® - V I fl u i d s . T r a n s m i s s i o n s r i o r t o t h e a b o v e s e r ia l n u m b e r s a r e n o t o m p a t i b l e w i t h D e x r o n ® - V I fl u i d s . S e a l o m p a t ib i l i t y c a n b e id e n t ifi e d b y a " D 6 C " o r c o lo r m a r k s o n t h e f a c e o f t h e s e a l. S e e I L 6 - W T - 0 7 f o r m o r e in f o r m a t io n .

2 . In s ta ll s e a lr in m a r k s c lu t c h

1 1 6 g (1 ) C 1 h u b

m m 7 ) a p is a s s

ID (w n d 1 0 to n s e e m b ly

it h p in 1 m m a l r in g (1 2 ) .

k m ID (1 8 L u

a rk s ( w ith ) in t o b e s e

) C lig ro a lr

2 p i s t o n h t b l u e t a t i n g in g s .

3 . L u b r ic a t e t h e C 2 p is to n O D a n d I D . I n s t a ll a n e w C 2 p i s t o n s e a l r in g ( 1 9 ) o n C 2 p i s t o n ( 2 0 ) . I n s t a l l C 2 p i s t o n ( 2 0 ) i n t o t h e r o t a t i n g c l u t c h

5 - 2 0

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4 . L u b r ic a te t h e C 1 p is to n O D a n d I D . I n s ta ll a n e w 1 7 9 m m I D ( w it h o ra n g e m a rk s ) C 1 p i s t o n s e a l r in g ( 1 8 ) o n C 1 p i s t o n ( 2 4 ) . L u b e t h e in s id e b o r e a n d O D s e a lr in g o n t h e C 1 p i s t o n ( 2 4 ) . A l i g n i n g s l o t i n C 1 p i s t o n ( 2 4 ) ( F i g u r e 5 – 3 2 , V ie w D ) w it h a n y lu b e o r ifi c e o n t h e r o t a t i n g c l u t c h h u b , i n s t a l l C 1 p i s t o n ( 2 4 ) in t o t h e c e n t e r o f C 2 p i s t o n ( 2 0 ) . W it h a s o f t m a l l e t , l i g h t l y t a p C 1 p i s t o n ( 2 4 ) u n t i l i t i s f u l l y s e a t e d a t t h e b o t t o m o f C 2 p i s t o n ( 2 0 ) . N S S S S s w p c c 8 S

O T E : B e g i n n i n g w i t h S / N 6 5 1 0 7 1 7 2 8 1 , / N 6 5 2 0 0 8 3 0 9 3 , S / N 6 6 1 0 2 2 0 9 9 0 , / N 6 6 2 0 0 0 5 8 2 1 , S / N 9 3 7 0 0 0 7 6 6 1 , / N 9 3 2 0 0 0 6 2 3 1 , S / N 9 4 7 0 0 0 6 0 8 0 , / N 9 4 2 0 0 0 7 5 6 0 , m a t e r ia l o f s p e c ifi c e a l s h a s b e e n m o d i fi e d t o b e c o m p a t i b l e i t h D e x r o n ® - V I fl u i d s . T r a n s m i s s i o n s r io r t o t h e a b o v e s e r ia l n u m b e r s a r e n o t o m p a t i b l e w i t h D e x r o n ® - V I fl u i d s . S e a l o m p a t i b i l i t y c a n b e id e n t i fi e d b y a " D 6 C " o r c o lo r m a r k s o n t h e f a c e o f t h e s e a l. S e e I L 6 - W T - 0 7 f o r m o r e in f o r m a t io n .

5 . P la c e t h is a s s e m b ly o n J 3 5 9 2 3 - 4 C o m p r e s s o r B a s e . I n s t a l l C 1 s p r in g a s s e m b l y ( 2 5 ) . 6 . I n s t a ll a n e w 2 0 2 m m I D ( w it h y e llo w m a r k s ) b a l a n c e p i s t o n s e a l r i n g ( 2 7 ) o n b a l a n c e p i s t o n ( 2 6 ) . L u b e t h e s e a lr in g . 7 . P a ( (

la c e s s e m 2 4 ) w F ig u r

b a la n c b ly (1 4 it h t h e e 5 – 3 2

8 . P r e - s ta J 3 5 9 2 o r ie n t e (2 5 ), w d o w n a

g e 3 -1 d to a s h n d

e p is to n ) , a lig n in c a s t b u m V ie w D )

s n a P is c o e r, c o m

p r in g to n S p m p re s a n d h a p re s s

( 2 6 ) o n r o t a t i n g c l u t c h g t h e n o t c h o n C 1 p i s t o n p o n b a l a n c e p i s t o n ( 2 6 ) .

(2 8 ). r in g C s C 1 s n d le . C 1 s p

In s ta o m p r p r in g T h re a r in g a

l l t o o l e s s o r ( a s s e m d th e h s s e m b

C 1 ) b ly a n d le ly ( 2 5 ) .

9 . I n s t a l l 1 0 4 m m I D e x t e r n a l r e t a i n i n g r i n g ( 2 8 ) i n g r o o v e c l o s e s t t o b a l a n c e p i s t o n ( 2 6 ) o f r o t a t in g c l u t c h h u b a s s e m b l y ( 1 4 ) . 1 0 . C a r e f u l ly r e l e a s e C 1 s p r i n g ( 2 5 ) a n d r e m o v e a l l t o o l s f r o m t h e a a s s e m b l y . 1 1 . I n s t a l l C 1 / C 2 a s s e m b l y i n t o r o t a t i n g c l u t c h d r u m ( 1 1 ) .


M O D U L E 1 2 . In s ta ll lo c a t in (1 1 ) (F a s s e m c lu t c h

C 2 s p g r in g ig u r e b ly p r d ru m

r in g a s s d o w n in 5 – 3 3 ). o p e r ly a (1 1 ) a n d

e m b l y ( 2 1 ) w i t h t h e i n n e r t h e r o t a t i n g c l u t c h d r u m M a k e s u r e t h e s p r in g l i g n s w i t h t h e r o t a t i n g C 2 p i s t o n s p lin e s .

R E B U IL D 3 – 6 h . B u t t - J o i n t S e a l r i n g s f o r m e t h o d a n d p r o c e d u r e . 1 7 . In s ro t (5 ) In s tu r c lo

t a l l t u r b i n e s h a f t a s s e m b l y ( 5 ) o r ( 8 ) i n a t i n g c l u t c h a s s e m b l y ( 3 ) s o t u r b i n e s h a f t o r ( 8 ) i s p o i n t i n g t o w a r d s t o r q u e c o n v e r t e r . t a l l t h e 4 8 m m I D r e t a i n i n g r i n g ( 1 6 ) i n b i n e s h a f t r e t a i n i n g r i n g g r o o v e l o c a t e d s e s t t o b u t t - jo i n t s e a l r i n g s ( 1 0 ) .

1 8 . In s ta ll 7 4 m m ID th r u s t b e a r in g ( t h e e n d o f r o t a t in g c lu t c h h u b a s ( 1 2 ) . W h e n i n s t a l l i n g t h r u s t b e a r c a r e t o o r i e n t t h e t h r u s t b e a r i n g to F i g u r e 3 – 4 s h o w n in 3 – 5 e . I n B e a r in g s . P o s itio n t h e a s s e m b ly t u r b i n e s h a f t d o w n w a r d . 1 9 .

1 5 ) o n t o s e m b l y i n g s , t a k e c o n s i s t e n t s p e c t in g w i t h t h e

I n s t a l l C 1 a p p ly p l a t e ( 2 9 ) o n t u r b i n e s h a f t ( 5 ) o r ( 8 ) .

2 0 . S t a r t i n g w i t h a C 1 f r i c t i o n p l a t e ( 3 0 ) , a l t e r n a t e l y i n s t a l l s i x C 1 f r i c t i o n p l a t e s ( 3 0 ) a n d fi v e C 1 r e a c t i o n p l a t e s ( 3 1 ) . N O in in a s

F i g u r e 5 – 3 3 . S p r i n g A s s e m b l y I n s t a l l a t i o n 1 3 . P la c e t h e a s s e m b ly o n J 3 5 9 2 3 - 4 C o m p r e s s o r B a s e s o t h a t t h e r o t a t in g c lu t c h d r u m ( 1 1 ) i s s u p p o r t e d b y t o o l t a n g s ( F i g u r e 5 – 3 2 , V i ee w C ) . I n s t a l l t o o l s J 3 5 9 2 3 - 3 P i s t o n S p r i n g C o m p r e s s o r ( C 2 ) a n d J 3 5 9 2 3 - 2 P is t o n S p r in g C o m p r e s s o r ( C 5 ) ( F i g u r e 5 – 3 2 , V ie w B ) , b e a r in g , w a s h e r , a n d h a n d l e . C o m p r e s s C 2 s p r in g a s s e m b ly ( 2 1 ) a n d in s ta ll 2 9 8 m m I D r e t a i n i n g r i n g ( 2 2 ) i n r e t a i n i n g r i n g g r o o v e ( F o ld o u t 7 - 2 ) . R e m o v e J 3 5 9 2 3 - 3 P is t o n S p r in g C o m p r e s s o r ( C 2 ) a n d J 3 5 9 2 3 - 2 P is t o n S p r in g C o m p r e s s o r ( C 5 ) . 1 4 . If in (6 C

re m s ta ) o o m

o v ll 2 r (9 p re

e d in 5 – 7 a . D 0 m m ID b u s ) u s in g to o ls s s o r (C 1 ) a n

is a s h in g J 3 5 d J 8

s e m (7 ) 9 2 2 0 9 2

b ly ( F in t o t u - 1 P is D r iv e

o ld o r b in to n H a

u t 7 - 2 ) , e s h a f t S p r in g n d le .

1 5 . I n s t a ll 2 5 . 1 m m I D ( b r o w n ) O - r in g ( 4 ) o n t h e c o n v e r t e r e n d o f t h e t u r b i n e s h a f t ( 6 ) o r ( 9 ) . 1 6 . I n s e r t t h r e e b u t t - jo in t s e a s e a lin g b o r e o f g r o u n d s ( F o ld o u t 7 - 1 ) a n d m e a s u w it h fe e le r g a u g e s . M a x s e a lr in g g a p f o r r e u s e is in c h ) . R e m o v e s e a lr in g s s le e v e b o r e a n d in s t a ll t h a s s e m b ly ( 5 ) o r ( 8 ) (F o ld

l r i n g s ( 1 0 ) i n t o t h e le e v e ( 1 6 ) o r ( 1 7 ) r e t h e e n d g a p im u m a l lo w a b l e 0 . 4 6 m m ( 0 . 0 1 8 f r o m t h e g r o u n d e m o n t u r b i n e s h a f t o u t 7 - 2 ) . R e f e r t o C o p y r ig h t ©

2 0 0 9

T E c le a 3 – 6 s e m

: F r i c t i o n p l a t e s s h o u l d b e s o a k e d n t r a n s m is s io n fl u i d a s d i s c u s s e d d . C lu t c h e s a n d P is t o n s p r io r t o b l y .

2 1 . I n s t a l l C 1 b a c k in g p l a t e ( 3 2 ) , b e v e l e d e d g e u p , o n l a s t i n s t a l l e d C C 1 f r i c t i o n p l a t e ( 3 0 ) . 2 2 .

I n s t a l l 1 0 4 m m I D e x t e r n a l r e t a i n i n g r i n g ( 3 3 ) i n r e t a i n i n g r i n g g r o o v e o f r o t a t i n g c l u t c h h u b ( 1 4 ) .

2 3 . In s ta ll C U s in g C fr ic t io n h u b (3 6 c o m p le ( 2 9 ) . 2 4 . W h e n to o r ie F ig u re B e a r in (3 5 ) o in s t a ll 2 5 . S ta a lte s ix (1 1

1 d r iv e h u b 1 d r iv e h u b a n d r e a c t io n ) u n t il t h e C te ly d o w n to

(3 (3 p 1 th

4 ) o v e 6 ) , a lig l a t e in s d r iv e h e C 1 c

r C 1 c lu n a n d lo id e t h e u b (3 6 ) lu t c h a p

i n s t a l l i n g t t h r u s t b e a r i n g s , t a n t t h e t h r u s t b e a r i n g c o n s i s 3 – 4 s h o w n in 3 – 5 e . I n s p e g s . In s ta ll o n e 7 4 m m ID th r n e a c h s id e o f C 2 d r i v e h u b th is a s s e m b ly o v e r C 1 d r iv e

tc c C s p

h p a c k . a t e e a c h 1 d r i v e e a t s ly p l a t e

k e c a r e t e n t t o c t in g u s t b e a r i n g ( 3 6 ) , a n d h u b ( 3 4 ) .

r t in g w it h a C 2 r e a c t io n p l a t e ( 3 7 ) , r n a t e l y i n s t a l l s i x C 2 r e a c t i o n p l a t e s a n d C 2 f r i c t i o n p l a t e s ( 3 8 ) i n s i d e r o t a t i n g d r u m ) .


5 - 2 1


S E R V IC E

N O in in a s 2 6 . In s ID re t p la


t a l l C 2 b a c k i n g p l a t e ( 3 9 ) . I n s t a l l 2 9 8 m m C 2 r e t a i n i n g r i n g ( 4 0 ) i n r o t a t i n g d r u m a i n i n g r i n g g r o o v e c l o s e s t t o t h e C 2 b a c k i n g t e ( 3 9 ) .

2 7 . If re m ( F o ld (4 3 ). B u s h B u s h d r iv e B o d y G e a r s u n g 6 .3 m 2 8 . In (4 re (1

o v e d in o u t 7 -2 ), U s in g J in g / G r o u in g In s ta b u s h in g B u s h in g B u s h in g e a r. T h e m b e lo w

s ta ll P 1 ). In s ta in in g 1 ) a b o

5 – 8 .

a .


5 – 7 a . D is a s s e m b ly i n s t a l l 6 8 . 1 6 4 m m m I D b u s h i n g 3 5 9 2 2 - 2 O il P u m p B o d y n d S le e v e B e a r in g / P 1 S u n G e a r l le r a n d J 8 0 9 2 D r iv e H a n d l e , ( 4 3 ) u n t il J 3 5 9 2 2 - 2 O il P u m p / G r o u n d S le e v e B e a r in g / P 1 S u n I n s t a l l e r i s fl u s h a g a i n s t t h e P 1 b u s h in g s h o u ld b e 5 . 7 m m t o th e P 1 s u n g e a r fa c e .

1 s u n ta ll 2 9 r in g g v e th e

g e a 8 m ro o P 1

r d m v e s u

r iv ID o f n -g

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C 3 /C 4 A N D M A IN M O D U L E

b a in in tin g d r iv

s s e m g r in g c lu tc e h u b

b ly ( 4 4 ) i n h d r u m ( 4 2 ) .

H O U S IN G

D i s a s s e m b l y ( F o l d o u t 8 - 1 ) . N O k e e th e n a m

T E p in e

: W th e fo rm p la t

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la c n a m c o r e re

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p la t e , t a m p o r ig i n a l n a m e p la t e .

1 . I f n a m e p la t e ( 2 4 ) is d a m a g e d , r e m o v e n a m e p l a t e r e t a i n i n g r i v e t o r s c r e w ( 2 5 ) a n d n a m e p la t e ( 2 4 ) . 2 . In s h o S p lim 3 . R o C h

p e u s lin its

e m f C 3 b o u s

c t t h e C 5 c l u t c h s p l i n e s i n s i d e t h e m a i n i n g ( 2 2 ) . R e f e r t o 3 – 5 j . I n s p e c t in g e d P a r t s f o r s p e c i fi c a t i o o n s a n d s e r v i c e . o v e 3 /C 4 a c k in g

t w e lv e b o lt s ( 2 ) ( M 1 0 x 1 . 5 x 9 0 ) c lu t c h a s s e m b ly ( 1 ) . R e m o v e p la t e a s s e m b l y ( 3 ) f r o m C 3 c lu t c h ( 1 1 ) .

e x c e s s i v e w e a r . I f a n y p l a t e h a s p e r c e i v a b l e w e a r o r d i s t o r t i o n , m e a s u r e t h e w e a r p l a t e s a t t h e c o n t a c t s u r f a c e . M in i m u m a l lo w a b l e t h i c k n e s s f o r r e u s e is 2 . 8 1 m m ( 0 . 1 1 1 in c h ) . C h e c k fl a tn e s s o f b a c k p la t e ( 3 ) a n d t h e w e a r p l a t e s . M a x i m u m a l l o w a b l e d i s t o r t i o n f o r r e u s e is 0 . 1 5 m m ( 0 . 0 0 6 in c h ) . R e m o v e e a c h w e a r p l a t e b y g e n t ly p r y in g t h e w e a r p l a t e f r o m t h e b a c k p l a t e . 5 . R e m o v e P 1 r in g g e a r ( 6 ) . I n s p e c t s p lin e s o f t h e P 1 r in g g e a r . M a x im u m a l lo w a b l e s p l in e w e a r f o r r e u s e is 0 . 3 8 m m ( 0 . 0 1 5 in c h ) . 6 . R e m o v e C 3 c l u t c h p a c k — fi v e f r i c t i o n p l a t e s ( 7 ) a n d fi v e s t e e l r e a c t i o n p l a t e s ( 8 ) . 7 . V is u a lly in d a m a g e o p e rc e iv a b th ic k n e s s a llo w a b le ( 0 . 0 8 7 in c r e u s e is 0 8 . M p r s a (

s p e r e x le w o f e th ic h ). .4 0

e a s u r e th e o il g la t e . M in im u m a e u s e is 0 . 2 0 m m lo t e r o s io n o f e a llo w a b le s lo t e r o 0 . 1 5 7 i n c h ) .

9 . V is u a lly in s p e c t fo r d a m a g e o r e h a s p e r c e iv a b le th e th ic k n e s s o f M in im u m a llo w a m m ( 0 .1 2 6 in c h fo r r e u s e is 0 . 4 0 1 0 . R e m s p r in p is t o If it h r e p la

o v e p g a s s n re tu a s p e c e .

C o p y r ig h t ©

ro o v e d e p th o f e llo w a b le g r o o v e ( 0 .0 0 8 in c h ). M c h fr ic t io n p l a t e . s io n fo r r e u s e is

a c h f r i c t i o n d e p t h f o r e a s u r e t h e M a x i m u m 4 . 0 0 m m

e a c h s te e l r e a c tio n x c e s s iv e w e a r . I f a w e a r o r d is to r t io n , e a c h s te e l r e a c tio n b le t h ic k n e s s f o r r e ) . M a x im u m a l l o w a m m ( 0 . 0 1 6 in c h ) .

is to n r e e m b lie s r n p la t e rc e iv a b

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e t u r n e c t r t i o n . ,

n m u b

1 1 . R e m o v e C 3 c lu t c h h o u s in g a s s e m b l y ( 1 3 ) . 1 2 . R e m o v e C 3 c lu t c h p is t o n ( 1 0 ) f r o m h o u s i n g ( 1 3 ) . 1 3 . I n s p e c t C 3 c lu t c h h o u s in g ( 1 3 ) .

4 . V is u a l ly in s p e c t t h r e e w e a r p l a t e s ( 5 ) o n C 3 c lu t c h b a c k p l a t e a s s e m b l y ( 3 ) f o r d a m a g e o r 5 - 2 2

c t e a c h f r i c t i o n p l a t e ( 7 ) f o r c e s s iv e w e a r . I f a n y p l a t e h a s e a r o r d i s t o r t i o n , m e a s u r e t h e a c h f r i c t i o n p l a t e ( 7 ) . M i n i m u m k n e s s f o r r e u s e i s 2 . 2 1 m m M a x im u m a llo w a b l e c o n e f o r m m ( 0 . 0 1 6 in c h ) .


C 3 c lu t c h

M O D U L E

N u s p

O T E : R e s e d fo r C o lu t io n in is to n s e a

2 1 . R e m o v e C 4 p is to n ( 1 7 ) f r o m h o u s i n g ( 1 8 ) .

c o m m e n d m a n u a l p a r t s c le a n e r 3 / C 4 h o u s in g s t o a v o i d c a u s t ic a u t o m a t i c c l e a n e r s d a m a g i n g l s u r f a c e s .

1 4 . V is u a lly in s p e c t e a c h w e h o u s in g ( 1 3 ) f o r d a m a g e a n y p la te h a s p e rc e iv a b m e a s u re t h e w e a r p la te s u r f a c e . M in im u m a llo w r e u s e is 2 . 8 1 m m ( 0 . 1 1 1 is n e c e s s a r y r e m o v e th e p r y in g t h e w e a r p la t e f r o

b .

1 8 . M e a s u p la te . re u s e s lo t e r a llo w a (0 .1 5 7 1 9 . M e a s te e th ic k M a x m m 2 0 . R e re t in s o r d is

c t e a c h fr c e s s iv e w e a r o r d is a c h fr ic t io k n e s s fo r M a x im u m m m (0 .0 1

re th e o il g M in im u m a is 0 .2 0 m m o s io n o f e a b le s lo t e r o i n c h ) .

s u re l re a c n e s s im u m (0 .0 1

th e th tio n p fo r re a llo w 6 in c h

m o v e p is to u r n s p r in g p e c t p is to n d is to r t io n . t o r tio n , r e p

A s s e m b l y ( F o l d o u t 8 - 1 ) .

a r p l a t e ( 1 2 ) i n c l u t c h o r e x c e s s iv e w e a r . I f le w e a r o r d i s t o r t io n , s a t t h e c o n ta c t a b l e t h i c k n e s s f o r i n c h ) . I f r e p l a c e m e n t w e a r p l a t e s b y g e n t ly m t h e b a c k p la t e . .

1 6 . R e m o v e C 4 c lu t c h p a c k — fi v e f r i c t i o n p l a t e s ( 1 4 ) a n d s i x s t e e l r e a c t i o n p l a t e s ( 1 5 ) . s p e r e x le w o f e th ic h ). .4 0

ic t io n p l a t e e a r. If a n y to r tio n , m e n p la te (1 9 r e u s e is 2 a llo w a b le 6 in c h ) .

r o o v e d e p th o f e llo w a b le g r o o v e ( 0 .0 0 8 in c h ) . M c h fr ic t io n p l a t e . s io n f o r r e u s e is

ic k n e s s a n la te 1 4 . M u s e is 3 . 2 0 a b le c o n e ) .

d c o n e in im u m m m (0 fo r re u

n r e tu r n p la te ( 1 a s s e m b l ie s a t ta c re tu r n p la te (1 6 If it h a s p e r c e iv a l a c e .

(1 9 p la a s u ). M .2 1 c o n

) f o r t e h a s r e t h e i n i m u m m m e f o r

a c h f r i c t i o n d e p t h f o r e a s u r e t h e M a x i m u m 4 . 0 0 m m o f e a llo .1 2 6 s e is

6 ) w ith h e d . V ) fo r d a b le d a m

a c h w a b l e i n c h ) . 0 . 4 0 f o u r i s u a l l y m a g e a g e o r

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2 0 0 9

t h e C 4 c lu t c h

2 2 . I n s p e c t C 4 c lu t c h h o u s in g ( 1 8 ) f o r d a m a g e .

1 5 . V i s u a l ly i n s p e c t t h e b a c k p l a t e f o r d a m a g e o r e x c e s s i v e w e a r . I f t h e p l a t e h a s p e r c e i v a b l e w e a r o r d i s t o r t io n , m e a s u r e f o r s t e p w e a r o f b a c k p l a t e ( 3 ) , m a x im u m a l lo w a b l e s t e p w e a r f o r r e u s e is 0 . 1 3 m m ( 0 . 0 0 5 in c h ) . M e a s u r e t h e c o n e o f C 3 b a c k p la t e ( 3 ) . M a x im u m a l lo w a b l e c o n e o f C 3 b a c k p l a t e f o r r e u s e is 0 . 1 5 m m ( 0 . 0 0 6 in c h ) . I f r e p l a c e m e n t i s n e c e s s a r y , r e m o v e t h e w e a r p l a t e s b y g e n t ly p r y in g t h e w e a r p l a t e f r o m t h e b a c k p l a t e .

1 7 . V is u a lly in d a m a g e o p e r c e iv a b th ic k n e s s a llo w a b le ( 0 .0 8 7 in c r e u s e is 0

R E B U IL D


O T E : B e g i n n i n g w i t h S / N 6 5 1 0 7 1 7 2 8 1 , / N 6 5 2 0 0 8 3 0 9 3 , S / N 6 6 1 0 2 2 0 9 9 0 , / N 6 6 2 0 0 0 5 8 2 1 , S / N 9 3 7 0 0 0 7 6 6 1 , / N 9 3 2 0 0 0 6 2 3 1 , S / N 9 4 7 0 0 0 6 0 8 0 , a n d / N 9 4 2 0 0 0 7 5 6 0 , m a t e r i a l o f s p e c i fi c e a ls h a s b e e n m o d i fi e d t o b e c o m p a t i b l e i t h D E X R O N ® - V I fl u i d s . T r a n s m i s s i o n s r i o r t o t h e a b o v e s e r i a l n u m b e r s a r e n o t o m p a t i b l e w i t h D E X R O N ® - V I fl u i d s . S e a l o m p a t ib i l i t y c a n b e id e n t ifi e d b y a " D 6 C " o r c o lo r m a r k s o n t h e f a c e o f t h e s e a l. S e e I L 6 - W T - 0 7 f o r m o r e in f o r m a t io n .

1 . I n s t a l l p i s t o n ( 1 7 ) in t o C 4 h o u s i n g ( 1 8 ) . 2 . I n s t a l l p i s t o n r e t u r n p l a t e ( 1 6 ) . 3 . In re re (1

s t a l l C 4 c lu t c h p a c k . S t a r t in g w it h a s t e e l a c t i o n p l a t e , a l t e r n a t e l y i n s t a l l s i x s t e e l a c t i o n p l a t e s ( 1 4 ) , a n d s i x f r i c t i o n p l a t e s 5 ) . N O in in a s


4 . If r e q u (1 2 ), p o f a n a c lu t c h

ir o r h

: F r i c t i o n p l a t e s s h o u l d b e s o a k e d n t r a n s m is s io n fl u i d a s d i s c u s s e d d . C lu t c h e s a n d P is t o n s p r io r t o b l y . e d , s it io b o r o u s

in s t a ll n e w n th e C 3 p r e s s w it h in g (1 3 ) fa

C 3 h o u s th e c in g

h o in g p is u p

u s in g w e (1 3 ) o n to n s id e ( F ig u r e

a r th o f 5 –

p l a t e s e b e d t h e C 3 3 6 ) .

5 . A lig n t h e p o s t o n t h e b a c k o f a w e a r p l a t e w it h o n e o f t h r e e c h a m f e r e d w e a r p la t e m o u n t in g h o l e s in t h e C 3 c lu t c h h o u s i n g ( 1 3 ) . 6 . L i g h t l y p r e s s t h e w e a r p l a t e u n t i l i t i s fl u s h t o 0 . 0 7 0 m m ( 0 . 0 0 2 7 in c h ) a b o v e fl u s h . 7 . R e p e a t S t e p s 4 t h r o u g h 6 , f o r e a c h o f t h e t w o r e m a i n i n g w e a r p l a t e s . 8 . L u b e s e a l s u r f a c e s o f C 3 c lu t c h p i s t o n ( 1 0 ) , a n d i n s t a l l t h e C 3 c l u t c h p i s t o n i n t o C 3 c l u t c h h o u s i n g ( 1 3 ) . 9 . I n s t a l l C 3 c lu t c h h o u s in g a s s e m b l y ( 1 3 ) w i t h c l u t c h p i s t o n ( 1 0 ) o n t o p o f t h e a s s e m b l e d C 4 c l u t c h h o u s i n g ( i t e m s ( 1 4 ) – ( 1 8 ) , F i g u r e 5 – 3 4 ) .


5 - 2 3

S E R V IC E


M a k e s u r e t h e i n d e x t a n g s o n t h e c lu t c h h o u s i n g s a r e a l ig n e d ( F ig u r e 5 – 3 5 ) a n d p i s t o n r e t u r n s p r in g s lo c a t e i n C 4 h o u s i n g p a c k e t s .

N O in in a s


1 3 . T o in s p o s it i o a rb o r fa c in g

: F r i c t i o n p l a t e s s h o u l d b e s o a k e d n t r a n s m is s io n fl u i d a s d i s c u s s e d d . C l u t c h e s a n d P is t o n s p r io r t o b l y .

t a l l n e w C 3 b a c k p la t e w e a r p l a t e s , n t h e C 3 b a c k p la t e o n t h e b e d o f a n p r e s s w i t h t h e C 3 c lu t c h p i s t o n s i d e u p .

1 4 . A lig n t h e p o s t o n t h e b a c k o f a w e a r p l a t e w it h o n e o f t h r e e c h a m f e r e d w e a r p la t e m o u n t in g h o l e s in t h e C 3 b a c k p la t e . 1 5 . L i g h t l y p r e s s t h e w e a r p l a t e u n t i l i t i s fl u s h t o 0 . 0 7 0 m m ( 0 . 0 0 3 in c h ) a b o v e fl u s h . 1 6 . R e p e a t S t e p s 1 2 t h r o u g h 1 4 , f o r e a c h o f t h e t w o r e m a i n i n g w e a r p l a t e s .

F i g u r e 5 – 3 4 . C 3 / C 4 C l u t c h H o u s i n g A s s e m b l y

1 7 . In (3 in m

s ta ) m o r a in

ll C u s d e r h o

1 8 . In s t a ll tw th r o u g h in t o t h e b o lts to

3 b a t b e to c u s in

c k p in d e o r re g (2

e lv th e C 4 5 1 –

e M C 3 c lu 6 1

l a t e a s s e m b l y ( 3 ) . B a c k p l a t e x e d w it h C 3 a n d C 4 h o u s in g s c t l y i n s e r t t h e a s s e m b l y i n t o 1 ) .

1 0 x 1 . 5 x 9 0 r e t a i n i n g b o l t s ( 2 ) b a c k p la t e a s s e m b l y ( 3 ) a n d t c h h o u s i n g ( 1 8 ) . T i g h t e n t h e N ∙ m ( 3 8 – 4 5 lb f t ) .

1 9 . I f r e m o v e d , i n s t a l l n a m e p la t e ( 2 4 ) a n d s c r e w ( 2 5 ) t o m a i n h o u s i n g ( 2 1 ) .

F i g u r e 5 – 3 5 . C 3 / C 4 C l u t c h H o u s i n g A s s e m b l y I n d e x T a n g s A l i g n e d 1 0 . I n s t a l l p i s t o n r e t u r n p l a t e s p r i n g r e t a i n e r a s s e m b l y ( 9 ) . 1 1 . I n s t a l l P 1 r i n g g e a r ( 6 ) s o it i s lo c a t e d o n C 3 w e a r p l a t e s . 1 2 . I n s t a l l C 3 c lu t c h p a c k . S t a r t in g w it h a s t e e l r e a c t i o n p l a t e , a l t e r n a t e l y i n s t a l l fi v e r e a c t i o n p l a t e s ( 8 ) , a n d fi v e f r i c t i o n p l a t e s ( 7 ) . 5 - 2 4

C o p y r i g h t © 2 0 0 9 A l l i s o n T r a n s m i s s i o n , I n c .

M O D U L E

R E B U IL D 5 – 9 .

M A IN

S H A F T M O D U L E

N O T E : • F e p P a

o r 3 0 0 0 P x c e p t 3 5 0 ro c e e d to ro d u c t F a n d 3 7 0 0 S

ro d 0 , a 5 – 9 m ily P M

u c t F a n d 3 7 a . D is M o d e o d e ls

m ily 0 0 S a s s e ls , E ) (F o

m o d e ls , P m o d e ls , m b ly ( 3 0 0 0 x c e p t 3 5 0 0 l d o u t 8 - 2 )

• F o r 3 5 0 0 m o d e l p r o c e e d t o 5 – 9 c . M o d u le D is a s s e m b l y - ( 3 5 0 0 T r a n s m is s io n M o d e l ) ( F o l d o u t 9 - 1 ) . • F o r t h e 3 7 0 0 S P m o d e l , p r o c e e d t o 5 – 9 e . M o d u le D is a s s e m b ly ( 3 7 0 0 S P T r a n s m is s io n M o d e l ) ( F o l d o u t 9 - 2 ) . a . D i s a s s e m b l y ( 3 0 0 0 P r o d u c t F a m i l y M o d e l s , E x c e p t 3 5 0 0 a n d 3 7 0 0 S P M o d e l s ) ( F o l d o u t 8 - 2 ) . 1 . R e m o v e s p ir a l r e t a in in g r in g ( 4 ) ( 4 8 m m

I D ) .

2 . R e m o v e P 2 s u n g e a r ( 6 ). 3 . R e m o v e t h r u s t b e a r in g ( 5 ) ( 5 5 m m I D ) a n d in s p e c t a s p e r 3 – 5 e . I n s p e c t in g B e a r in g s . R e p l a c e if n e c e s s a r y . 4 . R e m o v e b e a r in g s p a c e r ( 7 ) . 5 . R e m o v e s e le c t iv e s h im r e m o v e d .

( 1 ) , i f n o t p r e v i o u s ly

6 . R e m o v e t h r u s t b e a r in g ( 2 ) ( 7 8 . 5 m m I D ) , i f n o t p r e v io u s l y r e m o v e d , a n d in s p e c t p e r 3 – 5 e . I n s p e c t in g B e a r in g s . R e p la c e if n e c e s s a r y . 7 . R e m o v e P 3 s u n g e a r (8 ) fro m

F i g u r e 5 – 3 6 . I n s t a l l i n g W e a r P l a t e s

8 . In s p e M in im m m ( s h a ft M in im re u s e

c t u m 0 .7 jo u u m is

a n d m a llo w 8 7 in c rn a l O a llo w 4 2 .9 7

m a in s h a ft ( 9 ) .

e a s u r e m a in s h a ft p a b le p ilo t O D fo r r e u h ). In s p e c t a n d m e a D fo r th e P 2 p la n e ta a b le m a in s h a f t jo u r m m ( 1 . 6 9 2 i n c h ) .

ilo s e s u ry n a

t s . is 1 9 . 9 8 r e m a in b u s h in g . l O D f o r

9 . I n s p e c t f o r m a i n s h a f t s p l i n e w e a r . R e f e r t o 3 – 5 j. I n s p e c t in g S p l i n e d P a r t s f o r s p e c i fi c a t i o n s a n d s e r v i c e l i m i t s .

C o p y r ig h t ©

2 0 0 9


5 - 2 5

S E R V IC E


b . A s s e m b l y ( 3 0 0 0 P r o d u c t F a m i l y M o d e l s , E x c e p t 3 5 0 0 , 3 7 0 0 S P M o d e l s ) ( F o l d o u t 8 - 2 ) . N s a (

O T E : D o e le c t iv e s s s e m b ly . 1 ) is p e r fo

n o t in h im ( 1 M e a s rm e d

s ta ll th r u s t ) u n til fi n a l u re m e n t fo r d u r in g fi n a l

b e tra s e b u

a r in n s m le c ild u

g ( 2 ) o r i s s i o n t i v e s h i m p .

1 . I n s t a l l P 3 s u n g e a r ( 8 ) o n t o m a i n s h a f t ( 9 ) . 2 . I n s t a l l b e a r in g s p a c e r ( 7 ) . 3 . In s ta ll W h e n to o r ie F ig u re B e a r in

th r u s t b e in s t a l lin g n t th e th r 3 – 4 s h o g s .

a r in g t h r u s u s t b e w n in

(5 ) t b e a r in 3 – 5

(5 5 a r in g c e .

m m ID g s , ta k o n s is te In s p e c

) . e c a r e n t t o t in g

4 . I n s t a l l P 2 s u n g e a r ( 6 ) . 5 . I n s t a l l s p ir a l r e t a i n i n g r in g ( 4 ) ( 4 8 m m I D ) . C o m p r e s s t h e s p i r a l r e t a i n i n g r i n g t o l o c k i t in t o p la c e o n m a in s h a f t 9 . 6 . P r o c e e d to 5 – 1 0 . P 1 P L A N E T A R Y M O D U L E . c . M o d u l e D i s a s s e m b l y - ( 3 5 0 0 T r a n s m i s s i o n M o d e l ) ( F o l d o u t 9 - 1 ) . 1 . R e m o v e s p ir a l r e t a in in g r in g ( 4 ) ( 4 3 . 5 m m f r o m m a i n s h a f t ( 8 ) .

I D )

3 . R e m o v e t h r u s t b e a r i n g ( 6 ) ( 6 7 m m m I D ) a n d in s p e c t p e r 3 – 5 e . I n s p e c t in g B e a r in g s . R e p l a c e if n e c e s s a r y . 4 . R e m o v e s p a c e r ( 7 ) . c t a n d m u m a llo w 0 .7 8 7 in c jo u r n a l O u m a llo w is 4 2 . 9 7

e a s u r e m a in a b le p ilo t O D h ). In s p e c t a n D fo r P 2 p la n a b le m a in s h m m ( 1 . 6 9 2 in

N s a (

O T E : D o e le c t iv e s s s e m b ly . 1 ) is p e r f o

1 . In s ta ll s p m m ID ). c a r e to o to F ig u r e B e a r in g s

n o t i n s t a l l t h r u s t b e a r i n g ( 2 ) o r h i m ( 1 ) u n t i l fi n a l t r a n s m i s s i o n M e a s u r e m e n t f o r s e l e c t i v e s h i m r m e d d d u r i n g fi n a l b u i l d u p .

a c e r W h e n r ie n t 3 – 4 .

(7 ) a n in s t a t h e t t h s h o w

d th llin g r u s t n in

ru s t b e th r u s t b e a r in 3 – 5 e .

a r i n g 6 ( 6 7 b e a r i n g s , t a k e g c o n s i s t e n t I n s p e c t i n g

2 . I n s t a l l P 2 s u n g e a r ( 5 ) a n d s p i r a l r e t a i n i n g r in g ( 4 ) ( 4 3 . 5 m m I D ) . C o m p r e s s t h e s p ir a l r e t a i n i n g r i n g t o l o c k i t i n t o p l a c e o n m a i n s h a f t ( 8 ) . 3 . P ro c e e d to 5 – 1 0 . P 1 P L A N E T A R Y e . M o d u le D is a s s e m b ly (3 7 0 0 S P M o d e l ) ( F o l d o u t 9 - 2 ) .

M O D U L E .

T r a n s m i s s i o n

1 . R e m o v e s p ir a l r e t a in in g r in g ( 3 ) ( 4 8 m m

I D ) .

2 . R e m o v e P 2 s u n g e a r ( 5 ) a n d t h r u s t b e a r in g ( 4 ) ( 5 5 m m ID ) . 3 . R e m o v e s p a c e r ( 6 ) . 4 . R e m o v e P 3 s u n g e a r ( 7 ).

2 . R e m o v e P 2 s u n g e a r ( 5 ).

5 . In s p e M in im m m ( s h a ft M in im re u s e

d . M o d u l e A s s e m b l y ( 3 5 0 0 T r a n s m i s s i o n M o d e l ) ( F o l d o u t 9 - 1 ) .

s h a ft fo r re d m e e ta r y a f t jo u c h ) .

p ilo t s . u s e is 1 a s u re m b u s h in g rn a l O D

9 . 9 8 a in . f o r

6 . I n s p e c t f o r m a i n s h a f t s p l in e w e a r . R e f e r t o 3 – 5 j. I n s p e c t in g S p l i n e d P a r t s f o r s p e c i fi c a t i o n s a n d s e r v i c e l i m i t s .

5 . R e m o v e t h r u s t b e a rin g ( 1 ) ( 9 6 .3 6 m m 6 . In s p e c 8 . M in m m ( 1 O D . M m m (2 7 . M a m s M 4

t C 6 im u m .4 1 4 in im u .0 8 6

e a s u re llo w a b le m (0 .7 8 h a f t jo u r in im u m 2 .9 7 m m

b u s h in g jo u r a llo w a b le O i n c h ) . I n n s p e m a llo w a b le in c h ) .

th e fro p ilo t O 7 in c h n a l O D a llo w a (1 .6 9

n a D c t O

l O D o n m fo r re u s e P 3 b u s h i n D fo r r e u s

n t m a i n s h a f t p D p e r m it te d f o r ). In s p e c t a n d m fo r P 2 p la n e ta b l e jo u r n a l O D 2 in c h ) .

ilo re e ry fo

O D ) . a in is 3 g jo e is

s h 5 .9 u rn 5 2

a ft 2 a l . 9 8

t . M i n i m u m u s e i s 1 9 . 9 8 a s u r e m a in b u s h in g . r r e u s e i s

8 . I n s p e c t f o r m a i n s h a f t s p l i n e w w e a r . R e f e r t o 3 – 5 j . I n s p e c t in g S p l in e d P a r t s f o r s p e c i fi c a t i o n s a n d s e r v i c e l i m i t s . f. M o d u le A s s e m b ly (3 7 0 0 S P M o d e l ) ( F o l d o u t 9 - 2 ) .

T r a n s m i s s i o n

1 . I n s t a l l t h r u s t b e a r in g ( 1 ) ( 9 6 . 3 6 m m O D ) . W h e n i n s t a l l i n g t h r u s t b e a r i n g s , t a k e c a r e t o o r i e n t t h e t h r u s t b e a r i n g c o n s i s t e n t t o 5 - 2 6

C o p y r ig h t ©


M O D U L E

R E B U IL D

F i g u r e 3 – 4 s h o w n in 3 – 5 e . I n s p e c t in g B e a r i n g s .

a l lo w a b l e s t e p w e a r f o r r e u s e is 0 . 1 2 m m ( 0 . 0 0 5 i n c h ) .

2 . I n s t a l l P 3 s u n g e a r ( 7 ) .

8 . R e m o v e t h r u s t b e a r in g s ( 3 ) a n d ( 1 3 ) f r o m e a c h s id e o f P 1 p l a n e t a r y c a r r ie r ( 8 ) .

3 . I n s t a l l s p a c e r ( 6 ) . 4 . In s ta ll P 2 s u n (4 ) (5 5 m m ID b e a r in g s , t a k e c o n s is t e n t t o F I n s p e c t in g B e a

g e a r ). W h c a r e ig u re r in g s

(5 ) a n d th r u e n in s ta llin g t o o r ie n t t h e 3 – 4 s h o w n .

s t b th th r in

9 . In s p a n d In s p s e rv

e a r i n g r u s t u s t b e a r i n g 3 – 5 e .

e c P 2 e c ic e

t s p l in e w e a r o f P 1 p l a n e t a r y c a r r ie r ( 8 ) p l a n e t a r y r in g g e a r ( 1 4 ) . R e f e r t o 3 – 5 j. t i n g S p l i n e d P a r t s f o r s p e c i fi c a t i o n s a n d l i m i t s .

5 . I n s t a l l s p ir a l r e t a i n i n g r in g ( 3 ) ( 4 8 m m I D ) . C o m p r e s s t h e s p i r a l r e t a i n i n g r i n g t o l o c k i n t o p l a c e o n m a i n s h a f t ( 8 ) .

5 – 1 0 . a .

P 1 P L A N E T A R Y

M O D U L E

D i s a s s e m b l y ( F o l d o u t 1 0 - 1 ) . 1 . R e m o v e r e ta in in g r in g ( 2 ) ( 1 9 0 .2 m m f r o m P 2 r in g g e a r ( 1 4 ) .

O D )

F i g u r e 5 – 3 7 . C a r r ie r In d e x in g R in g b .

2 . R e m o v e P 2 r in g g e a r ( 1 4 ) . 3 . M e a s u r e t h e P 1 p la n e t a r y p in io n e n d p la y i n P 1 c a r r i e r a s s e m b l y ( 4 ) . W h e n e n d p l a y e x c e e d s 0 . 9 4 m m ( 0 .0 3 7 in c h ) fo r P 1 , P 2 , o r P 3 p in io n s , r e v ie w S e c t io n 3 . G E N E R A L O V E R H A U L I N F O R M A T I O N f o r i n s p e c t io n c r i t e r i a o f p i n i o n g e a r s , t h r u s t w a s h e r s , a n d c a r r i e r s . R e p l a c e a n y p a r t s t h a t d o n o t m e e t i n s p e c t i o n g u i d e l i n e s o r s e r v i c e s p e c i fi c a t i o n s i n t h i s s e c t io n o r T a b l e 7 – 1 . M e a s u r e a l l s ix p i n i o n g e a r s . 4 . R e m o v e r e t a in in g r in g ( 5 ) ( 1 5 9 .2 in d e x in g r in g ( 6 ) . In s p e c t in d e x in s t e p w e a r , fl i p o v e r in d e x in g r i n g if s te p w e a r is m in o r. R e p la c e th r i n g i f w e a r i s e x c e s s i v e ( F i g u r e s id e s o f t h e in d e x in g r in g h a v e s r e p l a c e t h e i n d e x i n g r i n g . 5 . R e m o v e s ix s p in d l e s ( 7 ) f r o m 6 . S lid e o u ( 9 ) ( 1 4 .5 t w o r o lle c a r r ie r a w it h th e

t e a c h m m r b e a s s e m fi v e r

7 . M e a s u re (1 4 .5 m m M in im u m fo r re u s e th e s te p w

p in io n ID ) a n d r in g s ( 1 b ly (8 ) . e m a in in

th e th ic k n e s ID ) a n d (1 th r u s t w a s h is 1 . 3 9 m m e a r o f e a c h

g e (1 1 ) R g

a r 2 ) fro e p p in

W e a r

A s s e m b l y ( F o l d o u t 1 0 - 1 ) . 1 . I n s t a l l t w o r o l l e r b e a r i n g a s s e m b l i e s ( 1 1 ) i n t o t h e c e n t e r o f a p i n i o n g e a r ( 1 0 ) ( F ig u r e 5 – 3 8 ) . I n s t a l l t h r u s t w a s h e r s ( 9 ) a n d ( 1 2 ) i n s i d e P 1 p l a n e t a r y c a r r i e r ( 8 ) . A l i g n t h r u s t w a s h e r t a n g s w i t h t h e s l o t s i n t h e c a r r i e r a n d r e t a i n t h e m w i t h o i l - s o l u b l e g r e a s e ( F i g u r e 5 – 4 0 ) . S l i d e t h e p i n i o n g e a r a n d b e a r i n g s e t s i n t o t h e s i d e o f t h e P 1 p l a n e t a r y c a r r i e r , b e t w e e n t h e t h r u s t w a s h e r s ( F ig u r e 5 – 4 1 ) . R e p e a t t h e p r o c e d u r e w it h t h e fi v e r e m a i n i n g p i n i o n g e a r s .

m m O D ) a n d g r i n g ( 6 ) f o r a n d r e u s e e i n d e x i n g 5 – 3 7 ) . I f b o t h t e p w e a r ,

P 1 c a r r ie r ( 8 ) .

(1 (2 m e a io

0 ), th ru s t w a 1 .5 m m O D th e P 1 p la n t th e p r o c e d n g e a r s .

s o f a ll 2 ) ( 2 1 .5 e r th ic k (0 .0 5 4 th ru s t w

th ru m m n e s in c h a s h

s t w O s p e ). M e r.

s h e r s ) , a n d e t a r y u r e

a s h e r s D ) . r m i t t e d e a s u r e M a x im u m

C o p y r ig h t ©

2 0 0 9

F i g u r e 5 – 3 8 . P i n i o n G e a r B e a r i n g I n s t a l l a t i o n


5 - 2 7

S E R V IC E


F i g u r e 5 – 3 9 . P i n i o n G e a r a n d B e a r i n g A s s e m b l e d

F i g u r e 5 – 4 1 . P i n i o n G e a r I n s t a l l a t i o n 2 . I n s t a l l s i x s p i n d l e s ( 7 ) s o t h e l o w e r s t e p i s p o s i t i o n e d f o r p r o p e r i n s t a l l a t i o n o f i n d e x i n g r in g ( 6 ) ( F ig u r e 5 – 4 2 ) .

F i g u r e 5 – 4 0 . P r o p e r T h r u s t W a s h e r O r i e n t a t i o n F i g u r e 5 – 4 2 . S p i n d l e I n s t a l l a t i o n 3 . I n s t a l l i n d e x i n g r i n g ( 6 ) ( F i g u r e 5 – 4 3 ) a n d r e t a i n i n g r in g ( 5 ) ( 1 5 9 . 2 m m O D ) .

5 - 2 8

C o p y r ig h t ©


M O D U L E

R E B U IL D P 2 o r P 3 p in io n s O V E R H A U L IN F c r it e r ia o f p i n i o n c a r r ie r s . R e p la c in s p e c t io n g u id e in th is s e c tio n o r o f a ll fo u r p in io n

F i g u r e 5 – 4 3 . I n d e x i n g R i n g I n s t a l l a t i o n 4 . If c o m p o n e n ts w e r e re p la c e n d p la y . W h e n e n d p la y m m ( 0 .0 3 7 in c h ) f o r P 1 , P r e v ie w S e c tio n 3 . G E N E R I N F O R M A T I O N f o r in s p e c p in io n g e a r s , th r u s t w a s h e R e p la c e a n y p a r ts th a t d o g u id e lin e s o r s e r v ic e s p e c s e c t io n o r T a b l e 7 – 1 . C h e g e a r s .

e d , c h e c k p i n i o n e x c e e d s 0 .9 4 2 o r P 3 p in io n s , A L O V E R H A U L t io n c r it e r ia o f r s , a n d c a r r ie r s . n o t m e e t i n s p e c t i o n i fi c a t i o n s i n t h i s c k a l l s i x p i n i o n

6 . I n s t a l l r e t a i n i n g r r i n g ( 2 ) ( 1 9 0 . 2 m m m I D ) i n g r o o v e o f P 2 r i n g g e a r ( 1 4 ) f o r r e t a i n i n g P 1 p l a n e t a r y c a r r i e r a s s e m b l y ( 4 ) t o t h e p l a n e t a r y r i n g g e a r . 7 . In s ta ll tw o a n d (1 3 ) (7 p la n e ta r y c th r u s t b e a r b e a r in g c o 3 – 5 e . In s p

5 – 1 1 . a .

th 4 a in

ru s t b .2 5 m r r ie r a g s , ta n s is te n e c t in g

e a r in g s ( 3 ) ( 7 4 .2 5 m m I D ) o n e o n e a c h s id s s e m b ly ( 4 ) . W h e n in k e c a r e t o o r ie n t th e t t o F ig u r e 3 – 4 s h o w B e a r in g s .


I D ) e o f P 1 s t a l l i n g t h r u s t n in

m

M O D U L E

D i s a s s e m b l y ( F o l d o u t 1 0 - 2 ) . 1 . R e m o v e r e ta in in g r in g ( 2 ) ( 1 9 0 .2 m m

O D ) .

4 . R e R e p in In s In d if c F ig

m o v e r e t a i n i n g r i n g ( 1 3 ) ( 1 5 9 . 2 m o v e i n d e x in g r i n g ( 1 2 ) . R e m o io n s p in d le s ( 1 1 ) f r o m P 2 c a r r ie p e c t in d e x in g r in g ( 1 2 ) fo r s te p e x in g r in g s m a y b e fl ip p e d o v e r o r n e r s a r e n o t a b n o r m a lly w o r n u r e 5 – 3 7 ) .

5 . S lid (7 ) tw o P 2 th e g e a

e o u t e a c h p ( 1 4 .5 m m ID r o lle r b e a r in p la n e t a r y c a p ro c e d u re w r s .

6 . M e a s u r e th (7 ) (1 4 .5 m M in im u m th r e u s e is 1 .3 s te p w e a r o a llo w a b le s ( 0 .0 0 5 in c h

5 . I n s t a l l P 1 p l a n e t a r y c a r r i e r a s s e m b l y ( 4 ) o n P 2 r in g g e a r ( 1 4 ) .

b .

, r e v ie w S e c t i o n 3 . G E N O R M A T IO N fo r in s p e c g e a r s , th r u s t w a s h e r s , e a n y p a r ts th a t d o n o t l in e s o r s e r v ic e s p e c ifi c T a b le 7 – 1 . M e a s u r e e n g e a r s .

7 . In s p e c (5 ) fo r b u s h in w ith h a w o o r n b

t b u w e a g ID m m e y o

8 . C c M 0

s p li n (5 ) a u m a m (0

h e a rr a x .3 8

c k ie r im m

in io n g e a r ( 9 ) a n d ( 1 0 ) ( 2 g s (8 ) (1 6 m r r ie r a s s e m b ith t h e th r e e

E R A L t io n a n d m e e t a t i o n s d p l a y

m m O D ) . v e f o u r r ( 3 ) . w e a r . a n d r e u s e d ( s e e

) , t h r u s t w a s h e r s 1 . 5 m m O D ) , a n d m I D ) f r o m t h e l y ( 5 ) . R e p e a t r e m a i n i n g p i n i o n

e t h i c k n e s s o f a l l t h r u s t w a s h e r s m ID ) a n d ( 1 0 ) ( 2 1 .5 m m O D ) . r u s t w a s h e r t h i c k n e s s p e r m i t t e d f o r 0 m m ( 0 . 0 5 4 in c h ) . M e a s u r e t h e f e a c h t h r u s t w a s h e r . M a x im u m t e p w e a r f o r r e u s e is 0 . 1 2 m m ) .

s h in r o r is 4 e r a n d s e w n d llo w .0 1

g (6 ) d a m 3 .2 0 n d c e r v ic e a P 3 a b 5 in

in s id a g e . m m h is e l e lim

e P 2 p M a x im (1 .7 0 1 if v is u a it s .

la n u m in c lly

e ta ry c a llo w h ). R e d a m a g

a r r i e r a b le m o v e e d o r

r b e t w e e n P 2 p la n e t a r y p l a n e t a r y r in g g e a r ( 1 4 ) . l e s p l in e w e a r f o r r e u s e is c h ) .

A s s e m b l y ( F o l d o u t 1 0 - 2 ) . 1 . If (6 J P J S In (F

re p la c e m e n t is n e c e s s a ry , p re s s b u s h ) ( 4 3 . 1 0 4 m m I D ) , u s i n g i i n s t a l l e r 3 5 9 2 2 - 1 T u r b in e S h a ft/O u tp u t S h a ft/P l a n e t a r y B u s h i n g I n s t a l l e r a n d d r i v e r 8 0 9 2 D r iv e H a n d l e , u n t il J 3 5 9 2 2 - 1 T u h a f t/O u t p u t S h a ft /P 2 P la n e t a r y B u s h in s ta l le r s e a t s a g a i n s t th e P 2 c a r r ie r h u ig u r e 5 – 4 4 ) .

i n g 2 r b i n e g b

2 . R e m o v e P 3 r in g g e a r ( 1 4 ) . 3 . M e a s u r e P 2 p la n e t a r y p in io n e n d p la y . W h e n e n d p la y e x c e e d s 0 . 9 4 m m ( 0 . 0 3 7 in c h ) fo r P 1 , C o p y r ig h t ©

2 0 0 9


5 - 2 9 9

S E R V IC E


F i g u r e 5 – 4 4 . B u s h i n g I n s t a l l a t i o n

F i g u r e 5 – 4 6 . P i n i o n G e a r B e a r i n g A s s e m b l y

2 . I n s t a l l t w o b e a r in g s e t s ( 8 ) ( 1 6 m m I D / 2 4 m m O D ) in t o t h e c e n t e r o f p in io n g e a r ( 9 ) ( F i g u r e 5 – 4 5 ) . I n s t a l l t h r u s t w a s h e r s ( 7 ) a n d ( 1 0 ) i n P 2 p l a n e t a r y c a r r i e r ( 5 ) , a l i g n t h r u s t w a s h e r t a n g s w i t h s l o t s i n t h e c a r r i e r ( 5 ) , a n d r e t a i n t h e m w i t h o i l - s o l u b l e g r e a s e ( F ig u r e 5 – 4 7 ) . S lid e t h e p i n i o n g e a r a n d t w o b e a r in g s e t s in t o t h e s id e o f t h e P 2 p l a n e t a r y c a r r i e r b e t w e e n t h e t h r u s t w a s h e r s ( F i g u r e 5 – 4 8 ) . R e p e a t t h e p r o c e d u r e w i t h t h e t h r e e r e m a i n i n g p i n i o n g e a r s .

F i g u r e 5 – 4 7 . P r o p e r T h r u s t W a s h e r O r i e n t a t i o n


5 - 3 0

C o p y r ig h t ©


M O D U L E

F i g u r e 5 – 4 8 . P i n i o n G e a r I n s t a l l a t i o n 3 . I n s t a l l f o u r s p i n d l e s ( 1 1 ) s o t h e l o w e r s t e p i s p o s i t i o n e d f o r p r o p e r i n s t a l l a t i o n o f i n d e x i n g r in g ( 1 2 ) ( F ig u r e 5 – 4 9 ) .

R E B U IL D

F i g u r e 5 – 5 0 . I n d e x i n g R R i n g I n s t a l l a t i o n 5 . If c o e n d 0 .9 4 g e a r

m p o n e n t s w e r e r e p l a c e d , c h e c k p i n i o n p la y . P in io n e n d p la y s h o u ld n o t e x c e e d m m ( 0 . 0 3 7 i n c h ) . C h e c k a l l f o u r p i n i o n s .

6 . I n s t a l l P 2 c a r r ie r ( 3 ) in t o P 3 r i n g g e a r ( 1 4 ) . 7 . I n s t a l l r e t a i n i n g r in g ( 2 ) ( 1 9 0 . 2 m m O D ) i n t o P 3 r in g g e a r ( 1 4 ) , r e t a i n i n g P 2 p l a n e t a r y c a r r i e r a s s e m b l y ( 4 ) . N O T E : • F o r w ith R E T to 5

m o o u t A R – 1 3

• F 5 5 p H

m o d 2 . R 3 . R c e e d U S IN

o r – 1 – 1 ro O

d e ls w it h tra n s fe r D E R M O . R E A R e ls E T E A to G

o u t r c a s e D U L C O V

w it h A R D E R C O 5 – 1 4 A N D

tra n s R M V E R . A D P 3 O

e ta rd e , s k ip E a n d E R M O fe O M A

r c a D U L O D P T E V E R H

r a 5 – p r D

n d 1 2 . o c e e d U L E .

s e , s k ip E a n d U L E a n d R A U L .

F i g u r e 5 – 4 9 . S p i n d l e I n s t a l l a t i o n 4 . I n s t a ll in d e x in g r in g ( 1 2 ) ( 1 5 9 . 2 m m O D , F i g u r e 5 – 5 0 ) a n d r e t a i n i n g r in g ( 1 3 ) .

5 – 1 2 .

R E T A R D E R

M O D U L E

a . D i s a s s e m b l y o f R e t a r d e r V a lv e B o d y ( F o l d o u t 1 1 A ) . 1 . R o c s b C o p y r ig h t ©

2 0 0 9

e m o v e n e p lu g o n tro l b u b a s s e o d y a s

n in e a s s e o d y a m b ly s e m b


M 8 x m b ly s s e m (4 6 ) a ly ( 6 4

1 .2 (8 2 b ly n d ) .

5 x ) re (6 4 re m

6 5 ta in ) to o v e

b o in g re t re

lt s ( 8 1 ) a n d t h e r e t a r d e r a r d e r h o u s i n g t a r d e r c o n t r o l

5 - 3 1

S E R V IC E


2 . R e m o v e s e p a r a t o r p la t e ( 6 3 ) . 3 . R e m o v e p lu g ( 7 0 ) ( 1 6 . 4 m m I D ) , O - r in g ( 6 9 ) , r e l a y v a l v e ( 6 6 ) , a n d s p r in g ( 6 7 ) . 4 . R e m o v e p lu g ( 7 2 ) ( 1 6 . 4 m m I D ) , O - r in g ( 7 3 ) , s p r in g ( 7 4 ) , a n d r e g u l a t o r v a l v e ( 7 5 ) . 5 . R e m w ith O - r in B ro w

o v c o g s n )

e r e ta in in g n n e c to r ( 7 7 (7 9 ) (2 9 m fr o m s o le n

p in ) a m o id

(7 6 ). s s e m ID ) a n a s s e

R e m b ly . d (8 m b ly

o v e s o le n o i d R e m o v e 0 ) ( 2 8 m m I D ( 7 7 ) .

6 . C h e c k t h e r e s is ta n c e o f ( P C S 5 ) r e t a r d e r v a r i a b l e b l e e d s o l e n o i d ( 7 8 ) . R e s i s t a n c e m u s t b e w it h in t h e r a n g e s h o w n o n F i g u r e 3 – 8 . b . D i s a s s e m b l y o f R e t a r d e r H o u s i n g ( F o l d o u t 1 1 A ) . 1 . R e m o v e f o u r M 1 0 x 1 .5 x 3 0 b o lts ( 8 9 ) r e t a i n i n g e i t h e r t h e r e m o t e m a n i f o l d ( 8 8 ) o r t h e r e t a r d e r h o u s i n g ( 4 6 ) . 2 . R e m o v e r e m o t e m a n if o ld ( 8 8 ) a n d g a s k e t ( 8 6 ) . 3 . If n o t a lr e a d s e n s o r b o lt (4 1 ) , o u tp u t O - r in g ( 4 0 ) o u tp u t s p e e 3 – 5 r. In s p e

y r e m o v e d , r e m o v e o u t p u t s p e e d ( 4 2 ) ( 1 5 . 6 m m I D B r o w n ) , r e t a i n e r s p e e d s e n s o r a s s e m b l y ( 3 9 ) , a n d f r o m t h e r e t a r d e r h o u s in g . C h e c k d s e n s o r r e s i s t a n c e . R e f e r t o c t i n g E l e c t r i c a l C o m p o n e n t s .

4 . I f n o t a l r e a d y r e m o v e d , r e m o v e M 8 x 1 . 2 5 x 2 0 t e m p e r a t u r e s e n s o r r e t a i n i n g b o l t ( 3 8 ) ( 7 . 6 m m I D B r o w n ) , b r a c k e t ( 3 7 ) , t e m p e r a t u r e s e n s o r a s s e m b l y ( 3 5 ) , a n d O - r i n g ( 3 6 ) f r o m t h e r e t a r d e r h o u s i n g . C h e c k t h e r e s i s t a n c e o f t h e t e m p e r a t u r e s e n s o r a n d r e p l a c e t h e s e n s o r i f i t i s d e f e c t i v e ( F i g u r e 3 – 8 ) . 5 . R e m o v e n in e M 8 x 1 . 2 5 x 2 5 b o l t s ( 5 2 ) , c o v e r (5 1 ) a n d g a s k e t (5 0 ) fro m th e b o tto m r e t a r d e r h o u s i n g ( 4 9 ) .

o f

6 . R e m o v e p lu g ( 4 7 ) a n d w a s h e r ( 4 8 ) f r o m r e t a r d e r h o u s i n g ( 4 9 ) . 7 . R e m o v e r e t a in in g r in g ( 4 3 ) ( 1 . 6 6 8 in c h O D ) a n d fl o w v a lv e p l u g ( 4 4 ) . 8 . T h S p a s to th e th e R e 5 - 3 2

r e a d th e J – 4 2 0 4 8 R e ta rd e r F lo w V r in g C o m p r e s s o r in t o th e a c c u m u la f a r a s it w ill g o a n d s till a llo w th e h b e a lig n e d w it h th e p lu g ( 5 7 ) . C o m p lu g ( 5 7 ) to r e lie v e th e s p r in g lo a r e t a in in g r in g ( 5 8 ) ( 1 . 6 6 8 in c h O D m o v e r e t a i n i n g r in g ( 5 8 ) . C a r e f u l ly

a l v e t o r p o r t a n d l e p r e s s d o n ) . r e l e a s e

C o p y r ig h t ©

th e s c o u n F lo w O - r in v a lv e

p r in g lo a d b t e r c lo c k w is e V a lv e S p r in g (5 6 ) (3 4 .6 (5 4 ), a n d p

y tu . R g C m m in (

r n in g e m o v o m p r ID ), 5 3 ) .

th e to e J – 4 2 e s s o r, s p r in g

o l h a n d 0 4 8 R e p lu g ( 5 (5 5 ), re

l e t a r d e r 7 ) , t a r d e r

9 . I f n o t p r e v io u s l y r e m o v e d , r e m o v e o i l s e a l a s s e m b ly ( 5 9 ) , u s in g J – 2 4 1 7 1 - A . S e a l R e m o v a l t o o l . 1 0 . R e J – J – B e

m o 3 5 9 4 7 3 lle v

v e 2 5 4 7 ille

1 1 . S u p p o r p la n e ta re m o v e J – 4 7 3 4 th r e a d e (1 2 ). D T o o l o n th e P 3 re ta rd e

b e a r in -2 S p a O u tp u s p r in g

g re n n e t S h w a

t a i n e r ( 6 0 ) u s in g r N u t W r e n c h a n d a f t H o l d i n g T o o l. R e m o v e s h e r ( 6 1 ) .

t r e ta r d e r h o u s in r y c a r r ie r a s s e m d fro m th e re ta rd 7 O u tp u t S h a ft H d s h o u ld e r o f th e r iv e J – 4 7 3 4 7 O u w it h a h y d r a u lic p la n e t a r y c a r r ie r r h o u s i n g .

g ( 4 9 ) s o t h e P 3 b l y ( 6 ) c a n b e e r h o u s i n g . P la c e o l d i n g T o o l a g a in s t t h e P 3 p l a n e t a r y c a r r i e r t p u t S h a f t H o l d i n g p r e s s o r a m a l le t u n t il i s s e p a r a t e d f r o m t h e

1 2 . R e m o v e r o lle r b e a r in g ( 6 2 ) ( 7 5 m m t h e r e t a r d e r h o u s i n g .

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1 3 . R e m o v e th re e a llo w r e m o v a l fro m th e re ta r d g a s k e t (3 0 ) w h re ta r d e r s ta to r ( 4 9 ) .

(3 3 ) m b ly o v e tw e e h o u s

M 1 0 x 1 .5 o f re ta rd e r e r h o u s in g ic h p r o v id e (2 7 ) a n d th

x 9 0 b o lt s s ta to r a s s e (4 9 ). R e m s a s e a l b e e re ta r d e r

t o ( 2 0 ) t h e n t h e i n g

1 4 . R e m o v e r o t o r ( 3 1 ) . I n s p e c t r o t o r h u b s p l i n e s f o r w e a r . R e f e r t o 3 – 5 j . I n s p e c t i n g S p l i n e d P a r t s . 1 5 . R e m o v e s h o o k - ty p e m a tin g b o s e a lr in g . e x c e e d s 9

e a lr in g ( s e a lr in g re s a n d R e p la c e 5 .6 7 m m

3 2 s m th

) (1 0 (2 9 ) e a s u e s e (3 .7 6

3 .9 8 m in a n d (3 2 ) re th e ID a lr in g s if 7 in c h ) .

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1 6 . R e m o v e b e a r in g c u p ( 4 5 ) u s in g J – 3 9 4 0 B e a r in g R a c e R e m o v e r if b e a r in g is n o t b e i n g r e u s e d . c . D i s a s s e m b l y o f P 3 P l a n e t a r y C a r r i e r A s s e m b l y ( F o l d o u t 1 1 A ) . 1 . R e m R e m b u s h (9 ) fo

o v e o v e in g r w

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o u t p u t s h a f t b u s h i n g . M a x i m u m a l l o w a b l e I D f o r r e u s e is 2 0 . 1 9 m m ( 0 . 7 9 5 in c h ) .

3 . R e m o v e o u t e r p is to n s e a lr in g ( 2 4 ) ( 2 5 8 . 7 m m I D c o lo r c o d e d w it h y e llo w m a r k s . ) f r o m C 5 c l u t c h p i s t o n ( 2 3 ) .

2 . I f r e p l a c e m e n t i s n e c e s s a r y , r e m o v e t a p e r e d b e a r in g ( 1 3 ) ( 7 5 m m I D ) f r o m P 3 c a r r ie r ( 1 2 ) w i t h b e a r i n g p u l l e r .


3 . M e a s u r e p i n i o n e n d p l a y o f a ll f o u r p i n i o n s . P i n i o n e n d p l a y s h o u ld n o t e x c e e d 0 . 9 4 m m ( 0 . 0 3 7 i n c h ) . N O T E : T h e s p i n d l e s a n d p i n i o n s d o n o t n e e d t o b e r e m o v e d b e f o r e r e m o v in g t h e o u t p u t s h a f t a s s e m b l y ( 7 ) . 4 . R e m o v e r e ta in in g r in g ( 1 0 ) ( 1 5 9 m m O D ) . R e m o v e i n d e x in g r i n g ( 1 1 ) . R e m o v e f o u r p i n i o n s p i n d l e s ( 1 5 ) . 5 . S lid e a n d ( 3 8 .0 2 c a r r ie th r e e

p in io n g e a r ( 1 1 9 ), a n d tw o b 5 m m O D ) f r o r (1 2 ). R e p e a re m a in in g p in

7 ), th ru s t w a s h e a r in g s ( 1 8 ) ( 2 m t h e s i d e o f P t th e p r o c e d u re i o n g e a r s .

e th 9 ). 1 .3 a r o te p ) .

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o f a ll th r u s t w a llo w a b le t h . 0 5 4 in c h ) . M ru s t w a s h e r. r e u s e is 0 . 1

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d . D i s a s s e m b l y o f R e t a r d e r S t a t o r A s s e m b l y ( F o l d o u t 1 1 A ) . 1 . R e m o v e O - r in g ( 2 8 ) ( 2 9 7 .1 m m a s s e m b l y ( 2 0 ) . W A c o m d u r in ju c o n

R N I N G : P p re s s e d . in g r e m o v a ry c a n o c c t r o l l e d .

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4 . R e m o v e in n e r p i s t o n s e a l r in g ( 2 5 ) ( 1 4 0 . 3 m m O D ) f r o m C 5 c lu t c h p i s t o n ( 2 3 ) .

e r s ( 1 6 ) 8 m m I D , 3 p l a n e t a r y w i t h t h e

5 . If b e a r in lis te d in IN F O R M to w a r d s a s s e m b R e m o v e

6 . I n s p e c t in d e x in g r in g ( 1 1 ) f o r m in o r w e a r . T h e y m a y b e fl ip p e d o v e r a n d r e u s e d i f c o r n e r is n o t a b n o r m a l ly w o r n ( s e e F ig u r e 5 – 3 7 ) . 7 . M e a s u r e th (1 6 ) a n d (1 f o r r e u s e is th e s te p w e a llo w a b le s ( 0 .0 0 5 in c h


g c u S e c A T I th e ly ( 2 r .

p (2 6 ) t io n 3 . O N , re C 5 p is 0 ) u s in

d o e G E m o to n g J

s n o t N E R A v e b y s id e o – 3 9 4 0

m e e L O p re s f s ta B e a

t g u i d e l in e s V E R H A U L s in g o u t t o r h o u s i n g r in g R a c e

6 . R e p l a c e a n y p a r t s t h a t d o n o t m e e t g e n e r a l i n s p e c t i o n g u i d e l i n e s l i s t e d i n S e c t i o n 3 . G E N E R A L O V E R H A U L I N F O R M A T IO N . e .

A s s e m b l y o f R e t a r d e r S t a t o r ( F o l d o u t 1 1 A ) . 1 . I f b e a r in g c u p ( 2 6 ) w a s r e m o v e d , i n s t a l l a n e w b e a r i n g c u p i n t h e s t a t o r h o u s in g a s s e m b l y ( 2 0 ) . T o i n s t a l l , p l a c e J – 3 5 9 2 2 - 3 O u t p u t B e a r in g C u p I n s t a l le r o n J – 3 5 9 2 2 B e a r i n g / B u s h i n g I n s t a l l e r w i t h h a n d l e J – 8 0 9 2 D r iv e H a n d l e . P la c e s t a t o r h o u s in g a s s e m b l y ( 2 0 ) s o t h e r e t a r d e r s id e o f t h e a s s e m b l y i s d o w n . I n s t a l l b e a r i n g c u p ( 2 6 ) o n J – 3 5 9 2 2 - 3 O u t p u t B e a r in g C u p I n s t a l le r s o t h e s i d e o f t h e b e a r i n g c u p w i t h t h e l a r g e r I D is o r ie n t e d t o w a r d t h e C 5 p i s t o n s id e o f t h e s t a t o r h o u s i n g a s s e m b l y ( 2 0 ) a f t e r i n s t a l l a t i o n . P r e s s t h e b e a r in g c u p ( 2 6 ) in t o t h e s t a t o r h o u s i n g a s s e m b l y ( 2 0 ) u n t i l i t c o n t a c t s t h e s h o u ld e r in t h e h o u s in g b o r e . 2 . I n s t a ll in n e r s e a l r in g ( 2 5 ) ( 1 4 0 . 3 m m C 5 c l u t c h p i s t o n ( 2 3 ) .


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3 . In s ta ll o u te r c o lo r c o d e d p is to n ( 2 3 ) . s e a l b o re a r

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5 8 . 7 m m I D t o C 5 c lu t c h p i s t o n a n d t o r .

4 . A l i g n t h e t a b o n t h e b a c k o f t h e C 5 c lu t c h p i s t o n w i t h t h e n o t c h i n t h e r e t a r d e r s t a t o r h o u s i n g . L i g h t l y s e a t t h e C 5 c l u t c h p i s t o n ( 2 3 ) i n t o r e t a r d e r s t a t o r ( 2 7 ) . W A R N IN G c o m p re s s e in s t a lla tio n s p r in g fo r c

C A U s p r in to c a g ro o

: P i s t o n s p r i n g s d . B e e x tre m e ly . P e r s o n a l i n ju r y e is n o t c o n t r o lle

a r e h i g h l y c a r e f u l d u r i n g c a n o c c u r i f t h e d .

T I O N : U s e c a r e w h e n c o m p r e s s i n g g a s s e m b l y n o t t o a l l o w t h e a s s e m b l y t c h in a n d d a m a g e t h e r e t a i n i n g r in g v e .

5 . A lig n t h e t a b o n th e C 5 r e t u r n ( 2 2 ) w it h th e n o t c h in th e s ta t C o m p r e s s th e C 5 r e t u r n s p r in u s in g J – 3 5 9 2 3 - 2 P is to n S p r in In s t a ll r e t a in in g r in g ( 2 1 ) ( 1 2 8 t h e e n d s c le a r t h e t a b o f t h e s lo w ly r e le a s e t h e s p r in g f o r c J – 3 5 9 2 3 - 2 P is to n S p r in g C o m

s p r in g a s s e m b ly o r h o u s i n g ( 2 7 ) . g a s s e m b ly ( 2 2 ) g C o m p r e s s o r . m m I D ) s o a s s e m b l y , a n d e . R e m o v e t h e p r e s s o r .

6 . In s ta ll O - r in g s e a l ( 2 8 ) ( 2 9 1 . 7 m m r e t a r d e r s t a t o r ( 2 7 ) .

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( 1 3 ) s o th a t it th e r o lle r s fa c d o w n u n t il it c c a r r ie r ( 1 2 ) u s In s t a lle r /D r iv e

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r w i t h a r in g o n t h e P 3 t B e a r i n g

g ( 8 ) in t o - 1 T u r b i n e B u s h i n g d l e , u n t i l S h a f t / P 2 a g a i n s t

3 . I n s t a l l o u t p u t s h a f t a s s e m b l y ( 7 ) i n t o P 3 p l a n e t a r y c a r r i e r ( 1 2 ) . 4 . In s t a ll r e t a in in g r in g ( 1 4 ) ( 5 2 m m 5 . In s 3 8 b o P 3 ta n th e g e p la R e p in

I D ) .

t a l l t w o r o l l e r b e a r i n g s ( 1 8 ) ( 2 8 m m I D , .0 2 5 m m O D ) in s id e t h e p in io n g e a r ( 1 7 ) r e s . I n s t a l l t h r u s t w a s h e r s ( 1 6 ) a n d ( 1 9 ) i n p l a n e t a r y c a r r i e r ( 1 2 ) . A l i g n t h r u s t w a s h e r g s w i t h t h e s l o t s i n t h e c a r r i e r , a n d r e t a i n m w i t h o i l - s o l u b l e g r e a s e . S l i d e t h e p i n i o n a r w i t h r o l l e r b e a r i n g s i n t o t h e s i d e o f t h e P 3 n e t a r y c a r r ie r b e t w e e n t h e t h r u s t w a s h e r s . p e a t t h e p r o c e d u r e w i t h t h e t h r e e r e m a i n i n g i o n g e a r s .

6 . I n s t a l l f o u r p i n i o n s p i n d l e s ( 1 5 ) s o t h e l o w e r s t e p i s p o s i t i o n e d f o r p r o p e r i n s t a l l a t i o n o f i n d e x i n g r i n g ( 1 1 ) . 7 . I n s t a ll in d e x in g r in g ( 1 1 ) ( 1 5 9 m m r e t a i n i n g r i n g ( 1 0 ) .

O D ) . I n s t a l l

8 . If c o m p o n e n ts w e r e re p la c e d , m e a s u e n d p l a y . M a x im u m a l l o w a b l e p i n i o n p la y f o r r e u s e is 0 . 9 4 2 m m ( 0 . 0 3 7 in M e a s u r e a ll fo u r p in io n g e a r s . W h e n e x c e e d s 0 .9 4 2 m m ( 0 .0 3 7 in c h ) f o r P a n d P 2 p in io n s r e v ie w S e c t io n 3 . G E O V E R H A U L IN F O R M A T IO N fo r in s p c r ite r ia o f p i n i o n g e a r s , th r u s t w a s h e c a r r ie r s . R e p la c e a n y p a r t t h a t d o e s in s p e c t io n g u id e lin e s o r s e r v ic e s p e c in t h i s s e c t io n o r T a b l e 7 – 1 .

1 . I f r e m o v e d , i n s t a ll a n e w b e a r in g ( 1 3 ) o n t h e P 3 c a r r i e r . P o s i t i o n t h e c a r r i e r s o t h e o u t p u t s h a f t e n d i s f a c i n g u p . P l a c e b e a r i n g C o p y r ig h t ©

o n P re th e 5 9 2 .

2 . If r e m o v e d , d r iv e o r p r e th e o u t p u t s h a f t ( 9 ) w it h S h a ft/O u tp u t S h a ft/P 2 P In s t a lle r , a n d J – 8 0 9 2 D J – 3 5 9 2 2 -1 T u r b in e S h a P la n e t a r y B u s h in g In s t a o u t p u t s h a f t ( 9 ) .

f . A s s e m b l y o f P 3 P l a n e t a r y C a r r i e r A s s e m b l y ( F o l d o u t 1 1 A ) .

5 - 3 4

c e n te r s in g u p . o n ta c ts in g J – 3 S le e v e


r e p i n i o n e n d c h ) . e n d p la y 1 , P 2 N E R A L e c t io n r s a n d n o t m e e t i fi c a t i o n s

M O D U L E g . A s s e m b l y o f R e t a r d e r H o u s in g A s s e m b l y ( F o l d o u t 1 1 A ) . N S S S S s w p c c 8 S

R E B U IL D 6 . In th th ta

O T E : B e g i n n i n g w i t h S / N 6 5 1 0 7 1 7 2 8 1 , / N 6 5 2 0 0 8 3 0 9 3 , S / N 6 6 1 0 2 2 0 9 9 0 , / N 6 6 2 0 0 0 5 8 2 1 , S / N 9 3 7 0 0 0 7 6 6 1 , / N 9 3 2 0 0 0 6 2 3 1 , S / N 9 4 7 0 0 0 6 0 8 0 , a n d / N 9 4 2 0 0 0 7 5 6 0 , t h e m a t e r ia l o f s p e c ifi c e a ls h a s b e e n m o d i fi e d t o b e c o m p a t ib l e i t h D E X R O N ® - V I fl u i d s . T r a n s m i s s i o n s r io r t o t h e a b o v e s e r ia l n u m b e r s a r e n o t o m p a t i b l e w i t h D E X R O N ® - V I fl u i d s . S e a l o m p a t i b i l i t y c a n b e i d e n t i fi e d b y a " D 6 C " o r c o lo r m a r k s o n t h e f a c e o f t h e s e a l. S e e I L 6 - W T - 0 7 f o r m o r e in f o r m a t io n .

s t a ll e w a e w a n g in

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1 . I f b e a r in g c u p ( 4 5 ) w a s r e m o v e d , in s t a ll n e w a b e a r in g c u p in t h e r e t a r d e r h o u s in g ( 4 6 ) . T o i n s t a l l , p l a c e J – 3 5 9 2 2 - 3 B e a r i n g T o o l o n J – 3 5 9 2 2 B e a r i n g / B u s h i n g I n s t a l l e r s a n d J – 8 0 9 2 D r iv e H a n d l e . P la c e r e t a r d e r h o u s i n g s o r o t o r c a v i t y s i d e is d o w n . I n s t a l l b e a r in g c u p ( 4 5 ) o n J – 3 5 9 2 2 - 3 B e a r in g T o o l s o t h e s i d e w i t h t h e l a r g e r o u t s i d e d i a m e t e r i s p o s i t i o n e d t o w a r d s t h e o u t p u t y o k e / fl a n g e s i d e o f t h e r e t a r d e r h o u s i n g a f t e r i t ’ s i n s t a l l e d . P r e s s t h e b e a r in g c u p ( 4 5 ) in t o t h e r o t o r h o u s i n g a s s e m b l y ( 4 6 ) u n t i l t h e b e a r i n g c u p h a s c o n t a c t e d t h e s h o u l d e r i n s i d e t h e b e a r i n g b o r e o f t h e h o u s in g . 2 . P la c w o rk a s s e (1 3 )

e th e ta b le m b ly s it s in

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m b ly ( 6 ) o n t h e p ) a n d p l a c e s t a t o r t p u t s h a f t s o b e a r in g 6 ) .

3 . I n s t a l l r o t a t i n g s e a l r i n g s ( 2 9 ) a n d ( 3 2 ) o n t o r o t o r ( 3 1 ) a n d h o o k t h e m . I n s t a l l t h e r o t o r a s s e m b l y o n t h e o u t p u t s h a f t . 4 . In s ta ll a s s e m P la c e s h a ft a th e h o M 1 0 x 5 1 – 6 1 5 . In s ta J – 3 5 S le e b e a r h o u s h o u s

g a s k e t ( 3 0 ) b e t w e e n t h e s t a t o r b l y ( 2 0 ) a n d r e t a r d e r h o u s in g ( 4 9 th e re ta r d e r h o u s in g o v e r th e o u t n d a lig n th e h o le s o f th e h o u s in g le s o f th e s t a t o r a s s e m b l y . I n s t a ll 1 .5 x 9 0 b o lts ( 3 3 ) . T ig h te n th e b N ∙ m ( 3 8 – 4 5 lb f t ) .

l l r o l le 9 2 1 - 1 v e s o in g c u in g (4 i n g .

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v e r - tig h t e n in g b e a a m a g e b e a r in g r o ( 6 2 ) . If th e to r q u e o s it io n s in F ig u r e o u tp u t s p a n n e r n e d . B e s u re w re n L Y a s s h o w n in F

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P la c e t h e to r q u a r a s s h o w n in e w r e n c h in a c a n d t ig h te n t h e – 1 1 4 lb ft ) . I f t h d o n a tr a n s m is S M IS S IO N A S S n s fo r c o rre c t to

e w r e n c h a n d a F i g u r e 5 – 5 2 . R o t a t e o u n t e r c l o c k w i s e n u t t o 1 4 5 – 1 5 5 e r e t a r d e r m o d u l e s i o n , s e e S e c t i o n E M B L Y a s s e m b ly r q u e s p e c i fi c a t i o n s .

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s t a l l p in ( 5 3 ) r t th e v a lv e r p r in g ( 5 5 ) , O ( 5 7 ) . S p r in g d u n t il J – 4 2 0

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h a n d le c o u n te ) to c o n ta c t re ) a n d t o a llo w th e J – 4 2 0 4 8 C o m p re s s o r c m u la to r b o r e i s e .

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1 7 . I n s t a l l p l u g ( 4 7 ) , w a s h e r ( 4 8 ) . T i g h t e n p l u g ( 4 7 ) t o 6 0 – 6 7 N ∙ m ( 4 4 – 4 9 lb f t ) . 1 8 . I n s t a l l g a s k e t ( 5 0 ) , c o v e r ( 5 1 ) , a n d n i n e M 8 x 1 . 2 5 x 2 5 b o l t s ( 5 2 ) . T i g h t e n b o l t s t o 2 4 – 2 9 N ∙ m ( 1 8 – 2 1 lb f t ) . 1 9 . I n s t a l l r e m o t e m a n i f o l d ( 8 8 ) o r j u m p e r m a n i f o l d ( 8 7 ) a n d f o u r M 1 0 x 1 . 5 x 3 0 b o lt s ( 8 9 ) . T i g h t e n b o l t s t o 5 1 – 6 1 N ∙ m ( 3 8 – 4 5 lb f t ) . h . A s s e m b l y a n d I n s t a l l a t i o n o f R e t a r d e r C o n t r o l B o d y A s s e m b l y ( F o l d o u t 1 1 A ) .

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9 ) a n d ( 8 0 ) o n t o b l y ( 7 7 ) . I n s e r t t h r o u g h t h e b o r e 5 ) , a l ig n s o l e n o i d o i d r e t a i n i n g p i n - r in g s . A n a u d ib l e

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2 . I n s t a l l O - r i n g s e a l ( 8 4 ) a n d p r e s s u r e t a p p l u g ( 8 3 ) . T i g h t e n p l u g t o 1 0 – 1 3 N ∙ m ( 7 – 1 0 lb f t ) . 3 . I n s t a l l v a l v e ( 7 5 ) , s p r i n g ( 7 4 ) , l u b e d O - r i n g ( 7 3 ) , a n d p l u g ( 7 2 ) . T i g h t e n p l u g t o 2 4 – 2 9 N ∙ m ( 1 8 – 2 1 lb f t ) . 4 . I n s t a l l v a l v e ( 6 6 ) , s p r i n g ( 6 7 ) , l u b e d O - r i n g ( 6 9 ) , a n d p l u g ( 7 0 ) . T i g h t e n p l u g t o 2 4 – 2 9 N ∙ m ( 1 8 – 2 1 lb f t ) .

t o ( 5 8 ) f t h e l o w t o o l i t

1 6 . I n s t a l l t e m p e r a t u r e s e n s o r b r a c k e t ( 3 7 ) a n d M 8 x 1 . 2 5 x 2 0 t e m p e r a t u r e s e n s o r r e t a in in g b o l t ( 3 8 ) . T i g h t e n b o l t t o 2 4 – 2 9 N ∙ m ( 1 8 – 2 1 l b f t ) .

1 . In s ta ll a n s o le n o id c o n n e c to a t th e to p g r o o v e w (7 6 ), p u s

c lic k w i ll b e h e a r d a n d t h e t o p o f t h e s o l e n o i d w il l b e fl u s h w it h r e t a r d e r v a l v e b o d y ( 6 5 ) .

5 . I n s t a l l s o l e n o i d s e p a r a t o r p l a t e ( 6 3 ) o n r e t a r d e r c o n t r o l b o d y ( 6 5 ) . 6 . In s ta ll th to th e re n in e M 8 b o lts to

5 – 1 3 . a .

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y a s s e m b l y ( 6 4 ) b l y ( 4 6 ) . I n s t a l l ) a n d t ig h t e n f t ) .

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o t p r e v io u s ly e m b ly ( 3 8 ) u 4 1 7 1 - A S lid e s e n t, re m o v e

o v e d , re m 1 ), o u tp u t O - r in g ( 3 0 ifi c a tio n s . l C o m p o n e

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o i l s e a l t o o l S e t . I f h e r ( 4 0 ) .

3 . R e m o v e b e a r in g r e t a in e r n u t ( 3 7 ) u s in g J – 3 5 9 2 5 - 2 S p a n n e r N u t W r e n c h a n d J – 4 7 3 4 7 O u t p u t S h a f t H o l d i n g T o o l . 4 . R e m o v e B e l le v i lle s p r in g w a s h e r ( 3 6 ) . 5 . P la c e b l o c k s u n d e r r e a r c o v e r ( 2 8 ) o r ( 4 1 ) s o t h e P 3 c a r r ie r a s s e m b l y is f a r e n o u g h a b o v e t h e w o r k s u r f a c e t o a l lo w r e m o v a l f r o m t h e r e a r c o v e r . P la c e J – 4 7 3 4 7 O u t p u t S h a f t H o l d i n g T o o l a g a i n s t t h e t h r e a d e d s h o u l d e r o f t h e P 3 c a r r ie r a s s e m b l y . D r iv e o r p r e s s t h e c a r r i e r o u t w i t h J – 4 7 3 4 7 O u t p u t S h a f t H o l d i n g T o o l u n t i l t h e P 3 c a r r i e r a s s e m b l y s e p a r a t e s f r o m t h e r e a r c o v e r ( 2 8 ) o r ( 4 1 ) . 6 . R e m o v e r o lle r b e a r in g ( 3 5 ) a n d o u t p u t s p e e d s ig n a l w h e e l ( 3 3 ) f r o m r e a r c o v e r ( 2 8 ) o r ( 4 1 ) . 7 . I f t a p e r e d b e a r in g is g o i n g t o b e r e p l a c e d , P r e s s t h e b e a r i n g c u p ( 3 4 ) o u t t o w a r d s


M O D U L E y o k e / fl a n g e s id e u s in g J – 3 9 4 0 B e a r in g R a c e R e m o v e r . 8 . R e p g e n 3 . G th is

la c e ra E N m a

e a n y p a r t s t h a t d o n o t m e e t t h e l i n s p e c t i o n g u i d e l i n e s l i s t e d i n S e c t i o n E R A L O V E R H A U L I N F O R M A T IO N o f n u a l.

b . D i s a s s e m b l y o f t h e P 3 P l a n e t a r y C a r r i e r A s s e m b l y ( F o l d o u t 1 1 B ) . 1 . R e m o v e p i n ( 1 1 ) i f d a m a g e d o r i f r e m o v in g t h e b e a r in g a s s e m b l y ( 1 3 ) o r r e p la c i n g t h e o u t p u t s p e e d s ig n a l w h e e l ( 3 3 ) . 2 . I f r e p l a c e m e n t i s n e c e s s a r y , r e m o v e b e a r in g a s s e m b l y ( 1 3 ) w it h b e a r in g p u lle r . 3 . M e a s u r e t h e p i n i o n e n d p l a y o f a ll f o u r p i n i o n g e a r s . I f p in io n e n d p la y e x c e e d s 0 . 9 4 m m ( 0 . 0 3 7 in c h ) f o r P 1 , P 2 o r P 3 p in io n s , r e v ie w S e c tio n 3 . G E N E R A L O V E R H A U L I N F O R M A T I O N f o r in s p e c t io n c r it e r ia o f p i n i o n g e a r s , t h r u s t w a s h e r s , a n d c a r r ie r s . R e p l a c e a n y p a r t s t h a t d o n o t m e e t i n s p e c t i o n g u i d e l i n e s o r s e r v i c e s p e c i fi c a t i o n s i n t h i s s e c t io n o r T a b l e 7 – 1 .

R E B U IL D t h e I D o f t h e o u t p u t s h a f t b u s h i n g . M a x i m u m a l l o w a b l e i n s i d e d i a m e t e r f o r r e u s e i s 2 0 . 1 9 m m ( 0 . 7 9 5 in c h ) . c . D i s a s s e m b l y o f t h e R e a r C o v e r A s s e m b l y ( F o l d o u t 1 1 B ) . W c r s

A R N o m p r e m o v p r in g

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1 . R e m o v e t h e C 5 c lu t c h p i s t o n ( 2 4 ) f r o m t h e r e a r c o v e r ( 2 8 ) o r ( 4 1 ) b y c o m p r e s s in g t h e r e t a i n e r a n d s p r in g a s s e m b l y ( 2 3 ) ( 1 2 8 m m I D ) u s in g J – 3 5 9 2 3 - 2 P is to n S p r in g C o m p r e s s o r ( C 5 ) ( F ig u r e 5 – 5 4 ) . R e m o v e r e t a i n i n g r in g ( 2 2 ) w i t h s n a p r i n g p l i e r s a n d s l o w l y r e l e a s e t h e s p r i n g f o r c e .

N O T E : S p i n d l e s a n d p i n i o n s d o n o t n e e d t o b e r e m o v e d t o r e m o v e o u t p u t s h a f t a s s e m b l y ( 6 ) . 4 . R e m o v e r e ta in in g r in g ( 9 ) ( 1 5 9 m m O D ) . R e m o v e i n d e x i n g r i n g ( 1 0 ) . R e m o v e f o u r p l a n e t a r y s p i n d l e s ( 1 6 ) . 5 . S a s p g

lid e p in io n d (2 0 ), id e o f P 3 ro c e d u re e a r s .

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s s o f t h r u s t w a s h e r s ( 1 7 ) t h i c k n e s s a l l o w a b l e f o r . 0 5 4 in c h ) . M e a s u r e t h e r u s t w a s h e r . M a x im u m f o r r e u s e is 0 . 1 2 m m

7 . R e m o v e r e t a in in g r in g ( 1 5 ) ( 5 0 . 8 m m s p a c e r ( 1 4 ) .

F i g u r e 5 – 5 4 . C o m p r e s s i n g R e t a in e r a n d S p r i n g A s s e m b l y 2 . R e m o v e o u te r s e a lr in g ( 2 5 ) ( 2 5 8 .7 m m I D c o lo r c o d e d w it h y e llo w m a r k s ) f r o m t h e C 5 c l u t c h p i s t o n ( 2 4 ) .

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8 . I f n o t d o n e p r e v i o u s l y , r e m o v e o u t p u t s h a f t a s s e m b l y ( 6 ) . 9 . I n s p e c t t h e b u s h i n g ( 7 ) i n s i d e t h e e n d o f t h e o u t p u t s h a f t ( 8 ) f o r r e p l a c e m e n t . M e a s u r e C o p y r ig h t ©

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d o e s n o t m e e t th tio n 3 . G E N E R A T IO N , r e m o v e t h s s in g o u t t o w a r d o v e r (2 8 ) o r (4 1 ) e m o v e r .

e a n y p a r t s t h a t d o n o t m e e t t h e l i n s p e c t i o n g u i d e l i n e s l i s t e d i n S e c t i o n E R A L O V E R H A U L I N F O R M A T IO N o f n u a l.

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6 5 1 0 7 1 7 2 8 1 , 6 1 0 2 2 0 9 9 0 , 3 7 0 0 0 7 6 6 1 , 4 7 0 0 0 6 0 8 0 , a n d a t e r ia l o f s p e c ifi c t o b e c o m p a t ib le . T r a n s m i s s i o n s n u m b e r s a a r e n o t N ® - V I fl u i d s . S e a l t ifi e d b y a " D 6 C " o r e o f t h e s e a l. S e e f o r m a t io n .

1 . I f b e a r in g c u p ( 2 7 ) w a s r e m o v e d , i n s t a l l a n e w b e a r i n g c u p ( 2 7 ) i n r e a r c o v e r ( 2 8 ) o r ( 4 1 ) . T o i n s t a l l , p l a c e J – 3 5 9 2 2 - 3 O u t p u t B e a r i n g C u p I n s t a l l e r o n J – 3 5 9 2 2 B e a r i n g / B u s h i n g I n s t a l l e r a n d f a s t e n t o J – 8 0 9 2 D r iv e H a n d l e . P la c e r e a r c o v e r p i s t o n s i d e u p . I n s t a l l b e a r i n g c u p ( 2 7 ) o n J – 3 5 9 2 2 - 3 O u t p u t B e a r in g C u p I n s t a l le r s o t h e la r g e s t I D o f t h e c u p i s p o s it io n e d t o w a r d s t h e C 5 p i s t o n s id e o f t h e r e a r c o v e r a f t e r 5 - 4 0

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i n s t a l l a t i o n . P r e s s b e a r i n g c u p ( 2 7 ) i n t o t h e r e a r c o v e r u n t i l i t c o n t a c t s t h e s h o u l d e r . 2 . In C (2 m

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p i s t o n ( 2 4 ) i n t o n t h e t a b o n t h e it h t h e n o t c h f o r r .

4 . I n s t a l l t h e C 5 c l u t c h p i s t o n ( 2 4 ) i n t o r e a r c o v e r ( 2 8 ) o r ( 4 1 ) . W A R N IN G c o m p re s s e in s t a lla tio n s p r in g fo r c

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a r e h i g h l y c a r e f u l d u r in g c a n o c c u r i f t h e d .

T I O N : U s e c a r e w h e n c o m p r e s s i n g g a s s e m b l y n o t t o a l lo w t h e a s s e m b l y t c h in a n d d a m a g e t h e r e t a i n i n g r in g v e .

5 . A lig n t h e t a b o n t h e s p r in g r e t a i n e r a s s e m b l y ( 2 3 ) w i t h t h e n o t c h i n t h e r e a r c o v e r . C o m p r e s s t h e s p r in g a s s e m b ly ( 2 3 ) ( 1 2 8 m m I D ) a n d r e t a i n e r u s i n g p i s t o n s p r i n g c o m p r e s s o r J 3 5 9 2 3 - 2 P i s t o n S p r i n g C o m p r e s s o r ( C 5 ) . I n s t a l l t h e r e t a i n i n g r in g ( 2 2 ) s o t h e e n d s c l e a r t h e t a b i n t h e s p r i n g r e t a i n e r , a n d s l o w l y r e l e a s e t h e s p r in g f o r c e . e . A s s e m b l y o f t h e P 3 P l a n e t a r y C a r r i e r A s s e m b l y ( F o l d o u t 1 1 B ) . 1 . I f r e m o v m m ID ) s o th e o b e a r in g a n d th e b e a r in g th e P 3 c B e a r in g

e d , in s ta ll a n e w b e a r in g ( 1 3 o n t h e P 3 c a r r ie r . P o s it io n th u t p u t s h a f t e n d is fa c in g u p . ( 1 3 ) s o th a t it c e n t e r s o n th e r o lle r s a r e f a c in g u p . P r e s s d o w n u n til it c o n t a c t s t h e s h o a r r ie r ( 1 2 ) u s in g J – 3 5 9 2 1 - 1 I n s t a l l e r / D r i v e S l e e v e .

) ( 7 5 e c a r r i e r P l a c e c a r r i e r t h e u l d e r o n O u t p u t

2 . I n s t a l l a 1 2 m m ( 0 . 4 7 in c h ) r o l l p i n ( 1 1 ) t o a h e i g h t o f 2 . 3 5 – 2 . 9 5 m m ( 0 . 0 9 3 – 0 . 1 1 6 in c h ) a b o v e t h e c a r r ie r s h a f t . 3 . I f r e m o v e d , p r e s s b u s h in g ( 7 ) ( 2 0 m m I D ) i n s i d e t h e e n d o f t h e o u t p u t s h a f t ( 8 ) u s i n g J – 3 5 9 2 2 - 1 T u r b i n e S h a f t / O u t p u t S h a f t / P 2


M O D U L E P la n e t a H a n d le I n s t a l le s h a ft (8

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r y B u s h i n g I n s t a l l e r a n d J – 8 0 9 2 D r i v e u n t il J – 3 5 9 2 1 - 1 O u t p u t B e a r in g r / D r i v e S l e e v e s e a t s a g a i n s t o u t p u t ) .

4 . I n s t a l l o u t p u t s h a f t a s s e m b l y ( 6 ) in t o P 3 p l a n e t a r y c a r r i e r 1 2 . 5 . I n s t a ll r e t a in in g r in g ( 1 5 ) ( 5 0 . 8 m m F i g u r e 5 – 5 5 ) .

I D ,


F i g u r e 5 – 5 5 . R e t a i n i n g R i n g I n s t a l l a t i o n 6 . I n s t a l l t w o b e a r i n g s ( 1 9 ) ( 2 8 m m I D ) in s id e t h e p i n i o n g e a r ( 1 8 ) ( F ig u r e 5 – 5 6 ) . I n s t a l l t h r u s t w a s h e r s ( 1 7 ) a n d ( 2 0 ) in P 3 p l a n e t a r y c a r r i e r ( 1 2 ) . A l i g n t h e t h r u s t w a s h e r t a n g s w i t h t h e s l o t i n t h e c a r r i e r a n d r e t a i n t h e m w i t h o i l - s o l u b l e g r e a s e ( F i g u r e 5 – 5 8 ) . S l i d e t h e p i n i o n g e a r w i t h b e a r in g s i n t o t h e s id e o f t h e P 3 p l a n e t a r y c a r r ie r b e t w e e n t h e t h r u s t w a s h e r s ( F ig u r e 5 – 5 9 ) . R e p e a t t h e p r o c e d u r e w it h t h e t h r e e r e m a i n i n g p i n i o n g e a r s .

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2 0 0 9

F i g u r e 5 – 5 7 . P i n i o n G e a r w i t h B e a r i n g s I n s t a l l e d


5 - 4 1

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F i g u r e 5 – 5 8 . T h r u s t W a s h e r I n s t a l l a t i o n

F i g u r e 5 – 6 0 . P i n i o n S p i n d l e I n s t a l l a t i o n 8 . I n s ta ll in d e x in g r in g ( 1 0 ) ( 1 5 9 m m O D ) , ( F i g u r e 5 – 6 1 ) . I n s t a l l r e t a i n i n g r i n g ( 9 ) .

F i g u r e 5 – 5 9 . P i n i o n G e a r I n s t a l l a t i o n 7 . I n s t a l l t h e f o u r p i n i o n s p i n d l e s ( 1 6 ) s o t h e l o w e r s t e p i s p o s i t i o n e d f o r p r o p e r i n s t a l l a t i o n o f t h e in d e x i n g r in g ( 1 0 ) ( F ig u r e 5 – 6 0 ) .

5 - 4 2

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F i g u r e 5 – 6 1 . I n d e x i n g R i n g I n s t a l l a t i o n 9 . If c o m p o e n d p la y m m ( 0 .0 r e v ie w S IN F O R M g e a r s , th

n e n ts w e r e re p la c e d , . W h e n e n d p la y e x c 3 7 in c h ) fo r P 1 , P 2 o e c tio n 3 . G E N E R A L A T IO N fo r in s p e c t io n r u s t w a s h e r s , a n d c a


m e a s u r e p i n i o n e e d s 0 . 9 4 2 r P 3 p in io n s , O V E R H A U L c r i t e r i a o f p i n i o n r r i e r s .

M O D U L E

f . C o m p le tio n o f t h e R e a r C o v e r M o d u le ( F o l d o u t 1 1 B ) .

N O T E : W h e n e n d p l a y e x c e e d s 0 . 9 4 m m ( 0 . 0 3 7 in c h ) f o r P 1 , P 2 o r P 3 p in io n s , r e v ie w S e c tio n 3 . G E N E R A L O V E R H A U L I N F O R M A T I O N f o r in s p e c t io n c r i t e r i a o f p i n i o n g e a r s , t h r u s t w a s h e r s , a n d c a r r ie r s . R e p l a c e a n y p a r t s t h a t d o n o t m e e t i n s p e c t i o n g u i d e l i n e s o r s e r v i c e s p e c i fi c a t io n s i n t h i s s e c t io n o r T a b l e 7 – 1 . 1 0 . A lig n t h e s lo t in o u t p u t s p e e d s ig n a l w w it h s p r in g p i n ( 1 1 ) . U s in g J 3 5 9 2 1 - 1 B e a r in g In s t a lle r / D r iv e S le e v e , p r e s s s p e e d s ig n a l w h e e l ( 3 3 ) t o f u l l d e p t h c a r r ie r a s s e m b l y ( 5 ) ( F ig u r e 5 – 6 2 ) .

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1 . I f t h e b e a r in g c u p ( 3 4 ) w a s r e m o v e d , in s t a l l a n e w b e a r in g c u p in r e a r c o v e r ( 2 8 ) o r ( 4 1 ) . T o i n s t a l l , f a s t e n J – 8 0 9 2 D r iv e H a n d l e t o J – 3 5 9 2 2 B e a r i n g / B u s h i n g I n s t a l l e r s a n d p l a c e J – 3 5 9 2 2 - 3 O u t p u t B e a r i n g C u p I n s t a l l e r t o J – 3 5 9 2 2 B e a r i n g / B u s h i n g I n s t a l l e r s . P l a c e r e a r c o v e r ( 2 8 ) o r ( 4 1 ) C 5 p i s t o n s id e d o w n . I n s t a l l b e a r i n g c u p ( 3 4 ) o n J – 3 5 9 2 2 - 3 O u t p u t B e a r i n g C u p I n s t a l l e r p o s i t i o n e d s o w h e n i n s t a l l a t i o n i s c o m p l e t e t h e l a r g e r I D o f t h e c u p p o i n t s u p t o t h e y o k e / fl a n g e s id e o f t h e r e a r c o v e r ( 2 8 ) o r ( 4 1 ) . P r e s s t h e b e a r in g c u p ( 3 4 ) i n t o t h e r e a r c o v e r ( 2 8 ) o r ( 4 1 ) u n t i l i t c o n t a c t s t h e s h o u l d e r in s i d e t h e b o r e . 2 . P l a c e t h e P 3 c a r r ie r a s s e m b l y ( 5 ) o n t h e w o r k t a b l e ( w i t h t h e o u t p u t s h a f t u p ) a n d p l a c e r e a r c o v e r ( 2 8 ) o r ( 4 1 ) o v e r t h e o u t p u t s h a f t . F ig u r e 5 – 6 2 . O u tp u t S p e e d S ig n a l W I n s t a l l a t i o n

h e e l

3 . U s In s (3 5 w h

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2 0 0 9

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e a r in g s r o l l e r b e a r i n g o v e r ( 2 8 ) o r ( 4 1 ) , e m b l y .

e l l e v i l l e s p r i n g s w a s h e r ( 3 6 ) , s o t h e id e i s o n t h e y o k e / fl a n g e s i d e , a n d t i l t e r t o e n g a g e it s t a n g t o t h e in d e x in g e P 3 c a r r ie r .

A U T I O N : O u t ( 3 7 ) w ill d o n e (1 3 ) a n d re a k e r b a r p e v e r s e d , th e e o v e r-to r q u o s it i o n e d O N

A l l i s o n T r a n s m i s s i o n , I nn c .

v e r - tig h t e n in g b e a a m a g e b e a r in g r o ( 3 5 ) . If th e to r q u e o s it io n s in F ig u r e o u tp u t s p a n n e r n e d . B e s u re w re n L Y a s s h o w n in F

r i n g r e t a i n e r l le r s a n d w r e n c h a n d 5 – 5 2 a r e u t w ill c h e s a r e i g u r e 5 – 5 2 .

5 - 4 3

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F ig u r e 5 – 6 3 . R e ta in in g 5 . L u b r ic a t e b e a r in g r tr a n s m is s io n fl u id , b e a r in g r e t a in e r n u S h a f t H o ld in g T o o l N u t W r e n c h . P la c e b re a k e r b a r a s s h o th e to r q u e w re n c h d ir e c t io n a n d tig h t e ( 5 5 – 6 5 l b f t ) . 6 . S u p to r q m e a n u t 5 - 4 4

p o rt u e o s u re (3 7 )

re a r c f th e P d a fte ( F ig u r

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e t a i n e r n u t ( 3 7 ) w i t h c l e a n t h e n i n s t a l l a n d t i g h t e n t u s i n g J – 4 7 3 4 7 O u t p u t a n d J – 3 5 9 2 5 - 2 S p a n n e r t h e t o r q u e w r e n c h a n d a w n in F ig u r e 5 – 5 2 . R o t a t e i n t h e c o u n t e r c lo c k w is e n t h e n u t t o 7 4 – 8 8 N ∙ m

o v e r ( 2 8 ) o 3 c a r r ie r a r in s t a lla tio e 5 – 5 3 ). M

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8 . B e s u r e O - r in g ( 3 0 ) ( 1 5 . 6 m m I D ) is in p la c e a n d in s t a l l o u t p u t s p e e d s e n s o r a s s e m b l y


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( 2 9 ) . H o l d b r a c k e t ( 3 1 ) i n p l a c e a n d in s t a l l M 8 x 1 . 2 5 x 2 0 r e t a i n i n g b o l t ( 3 2 ) . T i g h t e n t h e b o l t t o 2 4 – 2 9 N ∙ m ( 1 8 – 2 1 lb f t ) . 9 . W h e n r e a r c o v e r ( 4 1 ) i s u s e d , b e s u r e t o i n s t a l l p l u g ( 3 9 ) a n d w a s h e r ( 4 0 ) . T o r q u e p l u g ( 3 9 ) t o 6 0 – 6 7 N ∙ m ( 4 4 – 5 0 lb f t ) .

F i g u r e 5 – 6 5 . P 3 C a r r i e r T u r n i n g T o r q u e C h e c k — M o d e ls W i t h o u t R e t a r d e r 6 . R e m o v e C 5 p is to n fr o m 7 . R e m ID . C in s id fro m F i g u r e 5 – 6 4 . P 3 C a r r i e r T u r n i n g T o r q u e C h e c k ― M o d e ls W i t h o u t R e t a r d e r

5 – 1 4 .

a .

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i s t o n s e a lr i n g ( 1 8 ) ( 2 5 8 . 7 m m e d W it h Y e llo w M a r k s ) a n d s e a l r i n g ( 1 9 ) ( 1 4 0 . 3 m m O D ) n .

8 . R e m o v e p lu g ( 2 2 ) f r o m t h e h o u s i n g .

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1 0 . R e m o v e fi lt e r s c r e e n ( 2 4 ) f r o m h o u s in g ( 2 0 ) . T h i s s c r e e n fi lt e r s m a i n s u m p fl u i d b e f o r e it e n t e r s t h e t r a n s f e r c a s e lu b e p u m p .

D i s a s s e m b l y ( F o l d o u t 1 7 - 2 ) . 1 . P l a c e a d a p t e r h o u s in g a s s e m b l y ( 1 4 ) o n J – 3 5 9 2 3 - 4 C o m p r e s s o r B a s e w it h o u t p u t e n d d o w n . 2 . I n s t a l l J – 3 5 9 2 3 - 2 P i s t o n S p r i n g C o m p r e s s o r ( C 5 ) a l o n g w i t h i t s w a s h e r , b e a r in g , a n d h a n d le . 3 . T h r e a d t h e h a n d le d o w n t o c o m p r e s s C 5 r e t u r n s p r in g a s s e m b l y ( 1 6 ) . 4 . R e m o v e r e ta in in g r in g ( 1 5 ) ( 5 0 . 8 m m

o v e o lo e lip th e

a d a p t e r h o u s in g ( 2 0 ) .

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5 . R e m o v e J – 3 5 9 2 3 - 2 P is to n S p r in g C o m p r e s s o r ( C 5 ) , R e m o v e C 5 r e t u r n s p r in g a s s e m b l y ( 1 6 ) . C A U T I O N : M a k e s u r e t h a t t h e C 5 r e t u r n s p r in g a s s e m b l y d o e s n o t c a t c h in t h e r e t a i n i n g r i n g g r o o v e .

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2 0 0 9

1 1 . M e a s u re g e a rs . W ( 0 .0 3 7 in r e v ie w S IN F O R M p in io n g e R e p la c e g u id e lin e s e c tio n o

p in io n e n d p h e n e n d p la c h ) fo r P 1 , P e c t io n 3 . G E A T IO N fo r in a r s , th r u s t w a n y p a r ts th a s o r s e r v ic e r 7 – 1 . W E A R

1 2 . R e m o v e r e ta in in ( 3 ) . I n s p e c t in d e fo r s te p w e a r . In o v e r a n d re u s e d w o rn (F ig u r e 5 – in d e x in g fl a t a r e r i n g .


l a y o f a l l f o u r p i n i o n y e x c e e d s 0 .9 4 m m 2 o r P 3 p in io n s , N E R A L O V E R H A U L s p e c t i o n c r i t e r i a o f a s h e r s , a n d c a r r i e r s . t d o n o t m e e t in s p e c t io n s p e c i fi c a t i o n s i n t h i s L IM IT S D A T A .

g r in g ( 2 ) a n d x in g r in g ( 1 2 ) d e x in g r in g s m if c o r n e r s a r e 3 7 ) . If b o th a r w o r n , r e p la c e

in d e x in g r in g ( 1 5 9 m m O D ) a y b e fl ip p e d n o t a b n o r m a l ly e a s o f t h e t h e i n d e x i n g

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1 3 . S lid e p in io n g e a r ( 9 m m I D , 3 6 .7 2 5 m m b e a r in g s ( 1 0 ) , fr o m c a r r ie r ( 5 ) . R e p e a t re m a in in g p in io n g e

b .

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n e s s o f th r u s t w a s a llo w a b le t h ic k n ( 0 .0 5 4 in c h ) . M e a th r u s t w a s h e r. M a r f o r r e u s e is 0 . 1

( 6 ) in s id e c a r g ( 6 ) . M a x im f o r r e u s e is 5 b u s h in g ( 6 ) w la c e m e n t is n

8 ) ( 2 4 t w o e t a r y t h r e e

h e r s ( 8 ) e s s f o r s u r e t h e a x im u m 2 m m

r ie r ( 5 ) . M u m a llo w 3 .2 2 m m it h a h a m e e d e d .

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A s s e m b l y ( F o l d o u t 1 7 - 2 ) . N S S S S s w p c c 8 S 1 . If H H in H

O T E : B e g i n n i n g w i t h S / N 6 5 1 0 7 1 7 2 8 1 , / N 6 5 2 0 0 8 3 0 9 3 , S / N 6 6 1 0 2 2 0 9 9 0 , / N 6 6 2 0 0 0 5 8 2 1 , S / N 9 3 7 0 0 0 7 6 6 1 , / N 9 3 2 0 0 0 6 2 3 1 , S / N 9 4 7 0 0 0 6 0 8 0 , a n d / N 9 4 2 0 0 0 7 5 6 0 , m a t e r ia l o f s p e c ifi c e a ls h a s b e e n m o d i fi e d t o b e c o m p a t i b l e i t h D E X R O N ® - V I fl u i d s . T r a n s m i s s i o n s r i o r t o t h e a b o v e s e r ia l n u m b e r s a r e n o t o m p a t i b l e w i t h D E X R O N ® - V I fl u i d s . S e a l o m p a t ib i l i t y c a n b e id e n t ifi e d b y a " D 6 C " o r c o lo r m a r k s o n t h e f a c e o f t h e s e a l. S e e I L 6 - W T - 0 7 f o r m o r e in f o r m a t io n . re m o u s a n d to c o u s

o v e d , u s e in g B u s h in le t o p r e s s a r r ie r ( 5 ) u in g B u s h in

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2 . In s ta ll tw o b e a r in m m O D ) in s id e p w a s h e rs (8 ) a n d ( 5 ) . A lig n th e t h r u in th e c a r r ie r a n d g r e a s e . S lid e t h e s e t s in t o t h e s id e b e tw e e n th e th r u p r o c e d u r e w ith t h g e a r s .

3 C a n d J ) (5 3 9 P 3 o n ta

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r / C 6 / C 7 9 2 D r i v e m m I D ) r r i e r / C 6 / C 7 c a r r i e r .

g s ( 1 0 ) ( 2 4 m m I D , 3 6 . 7 2 5 i n i o n g e a r ( 9 ) . I n s t a l l t h r u s t ( 1 1 ) i n P 3 p l a n e t a r y c a r r i e r s t w a s h e r t a n g s w i t h t h e s l o t r e t a i n t h e m w i t h o i l - s o l u b l e p i n i o n g e a r a n d b e a r in g o f t h e P 3 p l a n e t a r y c a r r i e r s t w a s h e r s . R e p e a t t h e e t h r e e r e m a i n i n g p i n i o n

3 . I n s t a l l f o u r p i n i o n s p i n d l e s ( 7 ) s o t h e l o w e r s t e p i s p o s i t i o n e d f o r p r o p e r i n s t a l l a t i o n o f i n d e x i n g r i n g ( 3 ) . 5 - 4 6

C o p y r ig h t ©

C A U T I O N : B e s u r e t h a t t h e p l a n e t a r y s p i n d l e s c a n n o t r o t a t e a f t e r t h e i n d e x i n g r in g h a s b e e n in s t a l le d o r lu b e fl o w t o t h e p in io n b e a r in g s m a y b e b lo c k e d . W h e n t h e in d e x i n g r in g s lo t s a r e w o r n o n o n e c o r n e r ( F i g u r e 5 – 3 7 ) , fl i p t h e p l a t e o v e r t o o b t a i n a n e w u n w o r n c o n t a c t s u r f a c e . I f b o t h c o n t a c t a r e a s a r e w o r n , r e p la c e t h e i n d e x i n g r in g . 4 . In s t a ll in d e x in g r in g ( 3 ) ( 1 5 9 m m r e t a i n i n g r i n g ( 2 ) . 5 . If c o m p o n e n ts w e r e re p la c e n d p la y . W h e n e n d p la y m m ( 0 .0 3 7 in c h ) fo r P 1 , P r e v ie w S e c tio n 3 . G E N E R IN F O R M A T IO N fo r in s p e c p in io n g e a r s , th r u s t w a s h e R e p la c e a n y p a r ts th a t d o g u i d e lin e s o r s e r v ic e s p e c s e c tio n o r 7 – 1 . W E A R L IM

O D ) . I n s t a l l

e d , m e a s u r e p i n i o n e x c e e d s 0 . 9 4 2 2 o r P 3 p in io n s , A L O V E R H A U L t i o n c r i t e r i a o f r s , a n d c a r r ie r s . n o t m e e t in s p e c t io n i fi c a t i o n s i n t h i s IT S D A T A .

6 . I n s t a l l a n e w fi lt e r s c r e e n ( 2 4 ) . M a k e s u r e t h e r o u n d m e t a l b o s s p r o p e r ly in d e x e s in t h e h o u s i n g . 7 . I n s ta ll a n e w O - r in g ( 2 3 ) ( 1 9 . 2 m m I D ) o n p lu g ( 2 2 ) , a n d t h e n in s t a l l t h e p l u g in t h e h o u s i n g . T i g h t e n t h e p l u g t o 3 4 – 4 7 N ∙ m ( 2 5 – 3 5 lb f t ) . 8 . In s a n C o L u

ta ll C d C 5 lo r C b e th

9 . In s ta o n th h o u s h o u s

ll e in in

5 p is p is to o d e d e s e a

t o n s e a l r in g ( 1 9 ) ( 1 4 0 . 3 m m O D ) n s e a lr in g ( 1 8 ) ( 2 5 8 . 7 m m I D . W it h Y e llo w M a r k s ) o n C 5 p is to n . lr in g s .

C 5 p is to n (1 p is to n w ith g . L ig h tly s e g ( 2 0 ) u s in g

7 ), a th e n a t th a s o

lig n in o t c h e p is ft fa c

g t h e c a s t t a b in t h e a d a p t e r t o n i n t o a d a p t e r e m a l le t .

1 0 . I n s t a l l C 5 r e t u r n s p r in g a s s e m b l y ( 1 6 ) . , a l ig n in g t h e n o t c h i n t h e h o u s i n g w i t h t h e t a b o n t h e r e t a i n e r . 1 1 . P l a c e a d a p t e r h o u s in g ( 2 0 ) o n t h e b a s e o f J – 3 5 9 2 3 - 4 C o m p r e s s o r B a s e w it h in p u t s i d e u p . 1 2 . In s ta ll (C 5 ). re tu rn s p r in g th e h o

J – T ig s p re u s

3 5 9 2 h te n r in g ta in e in g .

3 -2 th e a s s e r ta b

P is to h a n d m b ly in d e

n S le (1 x e

p r to 6 ). s w

in g c o m M a ith

1 3 . In s t a ll r e t a in in g r in g ( 1 5 ) ( 1 2 8 m m


C o p r k e th e

m p re e s s C s u re n o tc I D ) .

s s o r 5 t h a t h i n

M O D U L E 1 4 . R e le a s e s p r in g f o r c e a n d r e m o v e J – 3 5 9 2 3 - 2 P is t o n S p r in g C o m p r e s s o r ( C 5 ) a n d J – 3 5 9 2 3 - 4 C o m p r e s s o r B a s e .

5 – 1 5 . a .

S C A V E N G E

R E B U IL D 1 7 . M e a s u r e t h e p u m p b o d y g e a r c a v it y d e p th ( F ig u r e 5 – 6 6 ) . M a x i m u m a l lo w a b l e d e p t h f o r r e u s e is 1 5 . 2 1 5 m m ( 0 . 5 9 9 in c h ) .

P U M P O V E R H A U L

D i s a s s e m b l y ( F o l d o u t 1 9 - 1 ) . 1 . R e m o v e r e ta in in g p in ( 2 ) f r o m ( 3 ) .

p u m p h o u s in g

2 . R e m o v e s h a ft ( 4 ) . 3 . R e m o v e O - r in g s ( 5 ) ( 1 2 .4 m m ( 1 2 . 4 m m I D ) f r o m s h a ft ( 4 ) .

I D ) a n d ( 6 )

4 . R e m o v e t h r e e M 8 x 1 . 2 5 x 3 0 b o lt s ( 7 ) f r o m p u m p h o u s in g ( 3 ) . 5 . R e m o v e d r iv e n g e a r a s s e m b ly ( 8 ) a n d p u m p a s s e m b ly ( 1 3 ) f r o m p u m p h o u s in g ( 3 ) . 6 . R e m o v e th ru s t w a s h e r ( 1 2 ) fro m h o u s i n g ( 3 ) .

p u m p

7 . M e a s u r e t h e t h i c k n e s s o f t h r u s t w a s h e r ( 1 2 ) . M in i m u m a l lo w a b l e t h i c k n e s s f o r r e u s e i s 2 . 4 7 m m ( 0 . 0 9 7 in ) . 8 . I f t h r u s t w a s h e r ( 1 2 ) i s w o r n , d a m a g e d , o r d o e s n o t m e e t s p e c i fi c a t i o n s , r e p l a c e t h r u s t w a s h e r ( 1 2 ) . 9 . R e m o v e g a s k e t (1 8 ) fro m

F i g u r e 5 – 6 6 . M e a s u r i n g S c a v e n g e P u m p B o d y G e a r C a v i t y D e p t h 1 8 . M e a s u r e t h e p u m p b o d y g e a r c a v it y d ia m e t e r ( F i g u r e 5 – 6 7 ) . M a x im u m a llo w a b l e I D f o r r e u s e is 9 5 . 4 3 m m ( 3 . 7 5 7 in c h ) .

p u m p h o u s in g ( 3 ) .

1 0 . I n s p e c t f o r d a m a g e d b e a r in g s ( 9 ) a n d ( 1 0 ) in d r iv e n g e a r ( 1 1 ) . R e m o v e d a m a g e d b e a r in g s u s in g J – 2 4 1 7 1 - A S lid e H a m m e r a n d J a w S e t. 1 1 . R e m o v e f o u r M 8 x 1 . 2 5 x 2 0 b o lt s ( 1 9 ) f r o m p u m p a s s e m b ly ( 1 3 ) . 1 2 . R e m o v e p u m p c o v e r ( 1 4 ) , g e a r s e t ( 1 5 ) , a n d t h r u s t w a s h e r ( 1 6 ) f r o m p u m p b o d y ( 1 7 ) . 1 3 . M e a s u r e t h e t h i c k n e s s o f t h r u s t w a s h e r ( 1 6 ) . M in i m u m a l lo w a b l e t h i c k n e s s f o r r e u s e i s 2 . 4 7 m m ( 0 . 0 9 7 in c h ) . 1 4 . I f t h r u s t w a s h e r ( 1 6 ) i s w o r n , d a m a g e d , o r d o e s n o t m e e t s p e c i fi c a t i o n s , r e p l a c e t h e t h r u s t w a s h e r ( 1 6 ) . 1 5 . M e a s u r e t h e t h ic k n e s s o f p u m p c o v e r ( 1 4 ) . M in i m u m a l lo w a b l e t h i c k n e s s f o r r e u s e i s 6 . 7 5 m m ( 0 . 2 6 5 in c h ) .

F i g u r e 5 – 6 7 . M e a s u r i n g S c a v e n g e P u m p B o d y G e a r C a v i t y D i a m e t e r

1 6 . I f p u m p c o v e r ( 1 4 ) i s w o r n , d a m a g e d , o r d o e s n o t m e e t s p e c ifi c a t io n s , r e p l a c e p u m p c o v e r ( 1 4 ) .

1 9 . I f t h e p u m p b o d y g e a r c a v it y is w o r n , d a m a g e d , o r d o e s n o t m e e t s p e c ifi c a t io n s , r e p la c e t h e p u m p b o d y ( 1 7 ) .

C o p y r ig h t ©

2 0 0 9


5 - 4 7


S E R V IC E

2 0 . M e a s u r e t h e O D o f t h e o u t e r p u m p g e a r o f g e a r s e t ( 1 5 ) . M in im u m a llo w a b le O D f o r r e u s e is 9 5 . 2 0 m m ( 3 . 7 4 8 in c h ) . 2 1 . M e a s u r e t h e w id t h o f t h e d r iv e a n d d r iv e n p u m p g e a r s . M in im u m a llo w a b le w id t h f o r r e u s e is 1 5 . 0 8 m m ( 0 . 5 9 4 in c h ) . 2 2 . In s ta ll g e a r s M e a s u re th e ( F ig u r e 5 – 6 8 c le a r a n c e f o r

e t ( 1 p u m ). M re u s

5 ) p a x e

in t o p u m g e a r s id e im u m a llo is 0 . 1 3 m

p b o d y c le a r a w a b le m (0 .0 0

( 1 7 ) . n c e s id e 5 in c h ) .

F i g u r e 5 – 6 9 . M e a s u r i n g S c a v e n g e P u m p G e a r T o o t h T i p C l e a r a n c e 2 4 . M e (1 7 M a re u

a s ) ( x im s e

u re d r d ia m e u m a is 0 . 2

iv e n tr ic a llo w 3 m

g e a r l) c le a a b le d m (0 .0

(1 1 ra n ia m 0 9

) to c e e tr in c

p u m p b o d y ( F i g u r e 5 – 7 0 ) . i c a l c l e a r a n c e f o r h ) .

F i g u r e 5 – 6 8 . M e a s u r i n g S c a v e n g e P u m p B o d y G e a r S i d e C l e a r a n c e 2 3 . M e a s u r e g e a r t o o t h t i p c le a r a n c e ( F i g u r e 5 – 6 9 ) . M a x im u m a llo w a b l e c le a r a n c e f o r r e u s e is 0 . 1 3 m m ( 0 . 0 0 5 in c h ) .

F i g u r e 5 – 7 0 . M e a s u r i n g S c a v e n g e P u m p D r i v e n G e a r T o P u m p B o d y D i a m e t r i c a l C l e a r a n c e 2 5 . R e m o v e g e a r s e t (1 5 ) fro m 2 6 . If a s p e b o d 1 6

5 - 4 8

C o p y r ig h t ©

n y m c ifi c a y (1 7 th ro u

e a tio ) a g h

p u m p b o d y ( 1 7 ) .

s u r e m e n t d o e s n o t m e e t n s , r e p la c e g e a r s e t ( 1 5 ) o r p u m p n d r e p e a t m e a s u r e m e n t s in S t e p s 2 4 .


M O D U L E b .

A s s e m b l y ( F o l d o u t 1 9 - 1 ) . 1 . If (1 J – a n d r

r e m o v e d , in s ta ll n 0 ) in t o d r iv e n g e a 4 7 0 2 8 S c a v e n g e d J – 8 0 9 2 D r iv e H iv e r a g a in s t n u m b

e w b e a r in r ( 1 1 ) u s in P u m p B e a n d le . In s e re d b e a r

g s (9 ) a g a p re s a r in g In s ta ll b e a r in g c a g e

n d s a n d t a lle r i n g w i t h .

2 . I n s t a l l b e a r in g s ( 9 ) a n d ( 1 0 ) t o a d e p t h o f 3 m m ( 0 . 1 1 8 in c h ) . 3 . I n s t a l l n e w O - r i n g s ( 5 ) ( 1 2 . 4 m m ( 1 2 . 4 m m I D ) o n t o s h a f t ( 4 ) .

R E B U IL D s r w o

2 . R e m R e m w ith (4 4 )

6 . P o s it io n p u m p c o v e r ( 1 4 ) o n p u m p b o d y ( 1 7 ) a n d in s ta ll f o u r M 8 x 1 . 2 5 x 2 0 b o lt s ( 1 9 ) . T i g h t e n b o lt s ( 1 9 ) t o 2 4 – 2 9 N ∙ m ( 1 8 – 2 1 lb f t ) . 7 . A lig n t h e fl a t s o n t h e d r iv e n g e a r h u b w it h t h e fl a t s o n t h e in n e r g e a r s e t . S li d e d r iv e n g e a r a s s e m b ly ( 8 ) in t o p u m p a s s e m b ly ( 1 3 ) . 8 . I n s ta ll a n e w g a s k e t ( 1 8 ) , p u m p a s s e m b ly ( 1 3 ) , a n d d r iv e n g e a r a s s e m b l y ( 8 ) in t o p u m p h o u s i n g ( 3 ) . 9 . S e c u r e t h e p u m p a s s e m b ly ( 1 3 ) t o t h e p u m p h o u s in g ( 3 ) w it h t h r e e M 8 x 1 . 2 5 x 3 0 b o lt s ( 7 ) . T i g h t e n t h e b o l t s ( 7 ) t o 2 4 – 2 9 N ∙ m ( 1 8 – 2 1 l b f t ) . 1 0 . I n s t a l l t h r u s t w a s h e r ( 1 2 ) i n t o p u m p h o u s i n g ( 3 ) . 1 1 . I n s e r t s h a f t ( 4 ) in t o p u m p h o u s i n g ( 3 ) w i t h t h e h o l e i n t h e s h a f t ( 4 ) a l ig n e d w i t h t h e h o l e i n t h e p u m p h o u s in g ( 3 ) . 1 2 . I n s t a l l r e t a i n i n g p i n ( 2 ) i n t o p u m p h o u s i n g ( 3 ) t h r o u g h t h e h o le in s h a f t ( 4 ) . 1 3 . P r e s s r e t a in in g p in ( 2 ) fl u s h t o 0 . 2 5 m m ( 0 . 0 1 0 in c h ) b e l o w t h e p u m p h o u s in g g a s k e t s u r f a c e .

C A S E M O D U L E

a . D i s a s s e m b l y o f T r a n s f e r C a s e M o d u l e ( F o l d o u t 1 2 - 2 , F o l d o u t 1 3 , F o l d o u t 1 4 ) . 1 . If n o t p r e v io u s ly a s s e m b ly ( 1 ) o n s ta n d . P o s itio n o u tp u t is fa c in g d is a s s e m b ly b y s h a ft n u t ( 4 2 ) in

d o n e , in s ta l l t th e tr a n s m is s th e tra n s fe r c a u p . B e g in t h e lo o s e n in g t h e s t a lle d o n t h e

ra n io n s e tra fro fro

s fe r c a o v e rh s o th e n s fe r c n t o u tp n t o u tp

C o p y r ig h t ©

s e a u l f r o n t a s e u t u t 2 0 0 9

fi fte fro n a in m o v

e n M 1 0 x 1 .5 t o u t p u t h o u s h o is t a n d e y e e g a s k e t (5 0 )

x 4 0 b o lt s ( 4 5 ) . i n g ( 4 9 ) b y l i f t i n g b o l t s i n o o u t p u t y o k e .

4 . R o t a t e t h e fi x t u r e s o t h e r e a r o u t p u t e n d is f a c i n g u p .

5 . L u b r i c a t e g e a r s e t ( 1 5 ) a n d i n s t a l l t h e g e a r s e t in t o p u m p b o d y ( 1 7 ) .

T R A N S F E R

o v e o v e a c h . R e

) . L o o s e n t h e n u t b y i n s t a l l i n g a l a r g e t o o l ( f o r le v e r a g e ) a n d a n i m p a c t L e a v e t h e n u t in s t a l le d o n t h e f r o n t a f t .

3 . R e m o v e C 7 c lu t c h h o u s in g a s s e m b l y ( 5 8 ) .

I D ) a n d ( 6 )

4 . I n s t a l l t h r u s t w a s h e r ( 1 6 ) in t o p u m p b o d y ( 1 7 ) .

5 – 1 6 .

h a ft ( 5 7 e a c t io n re n c h . u tp u t s h

N O T E : R e f e r t o F o l d o u t 1 4 f o r S t e p s 5 t h r o u g h 1 1 . 5 . L o o th e L e a s h a

s e n r e a r o u t p u t s h a f t n u t ( 8 1 ) b y f o l l o w in g s a m e p r o c e d u r e e x p la i n e d i n S t e p 1 . v e t h e n u t in s t a l le d o n t h e r e a r o u t p u t f t .

6 . R n o a

o v e M 1 u t h e y e

e m in e u tp n d

s ix M 0 x 1 .5 o u s in g b o lts .

1 0 x x 1 0 (7 4 ) R e m

1 .5 x 4 0 b o lt s b y lif tin o v e g a

0 b (8 2 g w s k e

o lts ). R it h t (7

( 7 5 ) a n d e m o v e r e a r a c h a i n h o i s t 3 ) .

7 . R e m o v e P 4 c a r r ie r a s s e m b ly ( 5 7 ) . 8 . R e R e R e w h s o

m o m o m o e r e re a

v e v e v e th s s

fi fte e n b o lts ( 2 3 ) C 6 c lu t c h h o u s in C 6 c lu t c h h o u s i n e d iffe r e n t le n g th e m b ly w ill b e c o r

9 . R e m o r e a r id R e m o O - r in g p r o v id

v e le r v e (4 e d

fi v e M 1 0 x 1 .5 c o v e r (4 9 ) o n r e a r id le r c o v e 8 ) . U s e s m a ll in o r d e r t o r e m

1 0 . R e m o R e m o (4 2 ). a c c e s w ir in g

v e te n v e c o n R e m o v s to th e .

M 8 x 1 tr o ls c o i n g t h e c o n tro

.2 5 v e r c o n l v a

a n d tw g a s s e g g a s k b o lts w r e c t .

x 4 0 b o lt s to th e tra n r (4 9 ), g a s p ry b a rs a o v e th e c x 3 0 (4 3 ). t r o l s s lv e b

o b o lts m b ly ( e t (2 2 ) e re re

( 2 4 ) . 1 7 ) . . N o t e m o v e d

(5 0 ), h o s fe r c a s k e t (4 7 ) t lo c a t io o v e r .

b o lts ( 4 R e m o v c o v e r p o d y ( 2 9

ld in g e . , a n d n s

4 ) . e g a s k e t r o v i d e s ) a n d i t s

1 1 . R e m o v e t h e b o l t s s e c u r in g t h e r e a r t r a n s f e r c a s e t o t h e J – 3 8 5 7 2 T r a n s f e r C a s e H o ld in g F i x t u r e . N O T E : R e f e r t o F o l d o u t 1 2 - 2 f o r S t e p s 1 2 t h r o u g h 1 4 .


5 - 4 9

S E R V IC E


1 2 . R e m o v e t h e fi f t e e n M 1 0 x 1 . 5 x 1 0 0 b o lt s ( 1 7 ) s e c u r i n g t h e r e a r t r a n s f e r c a s e c o v e r ( 8 ) t o t h e f r o n t t r a n s f e r c a s e h o u s in g ( 7 ) . 1 3 . T h r e a d a n e y e b o lt i n t h e c e n te r o f t h e r e a r t r a n s f e r c a s e c o v e r ( 8 ) , t o l i f t i t . 1 4 . U s e fro n e n d a c c

a s t tra s o f o m p

o ft fa c e n s fe r c a th e c a s l is h s e p

m a lle t t o s e p a r a t e t h e r e a r a n d s e s . P r y p o i n t s a t o p p o s i t e e h a l v e s a r e a l s o p r o v id e d t o a r a t i o n .

1 5 . L ift a R e m th e d (3 9 ), b o d y (F o ld

n d r e m o v e t h e r e a r t r a n s f e r c a s e . o v a l o f t h e r e a r t r a n s f e r c a s e e x p o s e s r i v e g e a r ( 1 9 ) ( F o l d o u t 1 3 ) , i d l e r g e a r d r i v e n g e a r ( 8 0 ) , a n d c o n t r o l v a l v e ( 2 9 ) ( F o ld o u t 1 4 ) . R e m o v e g a s k e t ( 1 6 ) o u t 1 3 ) a n d r e p la c e it d u r in g a s s e m b l y .

1 6 . R e w ir 1 .2 (4 5

o v e th g h a rn x 2 5 b (F o ld o

m in 5 )

1 7 . R e m re m o s e c u c a s e

e o u e s s o lts u t 1

t p u t s p e e d s e n s o r a n d s o le n o id c o n n e c t o r s . R e m o v e t w o M 8 x ( 4 6 ) a n d o u t p u t s p e e d s e n s o r 4 ) .

o v e c o n t r o l v a lv e a s s e m b ly ( 2 9 ) a f t e r v i n g s i x M 8 x 1 . 2 5 x 5 0 b o lt s ( 4 1 ) r i n g t h e c o n t r o l v a l v e b o d y t o t h e t r a n s f e r .

1 8 . R e m o v e d r iv e n g e a r ( 8 0 ) , i d l e r g e a r ( 3 9 ) , a n d d r iv e g e a r ( 1 9 ) ( F o l d o u t 1 3 ) . 1 9 . R o t a t e t h e r e m a i n i n g a s s e m b l y , f r o n t o u t p u t e n d f a c in g u p . 2 0 . R e m o v e e ig h t M 1 0 x 1 . 5 x 3 5 b o lt s ( 4 ) , a n d t h e n r e m o v e lu b e c h a r g in g p u m p ( 5 ) . 2 1 . R e m o v e s h im p a c k A a n d k e e p it in t a c t f o r a s s e m b l y . S h i m p a c k A i s c r i t i c a l t o d r i v e g e a r e n d p l a y . 2 2 . R e m o v e e ig h t M 1 0 x 1 . 5 x 3 5 b o lt s ( 7 1 ) a n d m a n if o l d a s s e m b l y ( 7 2 ) . 2 3 . R e m o v e s h im p a c k C a n d k e e p it in ta c t f o r a s s e m b l y . S h i m p a c k C i s u s e d t o s e t u p d r iv e n g e a r e n d p l a y . 2 4 . R e m re m p a c U s e

o v e fi v e o v e fro n t k B (k e e p p ry b a rs

2 5 . R e m o v h a rn e s (2 9 ). R (3 2 ) s e tr a n s fe fo llo w e 5 - 5 0

e th e s c o n e m o c u r in r c a s d b y

M 1 id le in g a s

0 x 1 .5 r c o v e r it in t a c in r e m o

x 4 (2 3 t), a v a l

0 b ), O n d o f

n u t ( 8 8 ) s e c u r in n e c to r (3 1 ) to th v e th e fo u r M 8 x g th e c o n n e c to r e . R e m o v e c o n n th e h a r n e s s a n d

o lt s - r in g a s re a r

g th e e c o n 1 .2 5 p la te e c to r g a s k

(2 2 g (2 k e t id le

) , t h e n 4 ) , s h i m ( 2 8 ) . r c o v e r .

e l e c t r ic a l n e c t o r p l a t e x 2 5 b o lt s ( 2 9 ) t o t h e p l a t e ( 2 9 ) , e t ( 3 0 ) .

C o p y r ig h t ©

2 6 . R e m o v e fro m th e w it h a n O s c re e n w m a in tr a n c a s e s u m th e o v e rh

th e s u c t io n h o tra n s fe r c a s e . - r in g , a n d p r o h ic h fi lte r s t h e s m i s s io n s u m p . R e p la c e th a u l .

2 7 . In s p e c t b e a r in g o n th e fro n t tra n d a m a g e ; lik e w is (4 1 ), a n d (8 2 ) (F c a s e ( 2 ) (F o ld o u

s e fi ttin g T h e fi tt in v id e s a p fl u id re t u p fro m th e fi lt e r s c

c u p s (1 7 s fe r c a s e e , in s p e c o ld o u t 1 3 t 1 4 ) .

), (3 (1 4 t b e ) o n

7 ), ) fo a r in th e

(n g ilo rn e re

o t s is s t fo in g tra n e n

a n d r w e g c u re a

h o w n ) e a l e d r t h e t o t h e s f e r d u r in g

( 7 8 ) a r a n d p s ( 2 1 ) , r t r a n s f e r

2 8 . I f t h e b e a r in g c u p s m u s t b e r e p la c e d , u s e a h a m m e r a n d d r if t t o d r iv e t h e m o u t . 2 9 . D u r in g th e b e a r in g c u p in s t a l la in s t a ll th e lu b e c h a r g in g p u m p w it h t h e a p p r o p r ia t e s h im p a c b e a r in g c u p in t h e h o u s in g . S c u p d o e s n o t h a v e a n a c tu a l h o u s in g , lo c a t in g t h e b e a r in g e s s e n t ia l f o r p r o p e r g e a r e n d

t i o n , t e m p o r a r i l y o r t h e m a n i f o l d k t o lo c a t e t h e i n c e t h e b e a r i n g s e a t in t h e c u p c o r r e c t l y i s p l a y .

3 0 . I n s t a l l t h e b e a r in g c u p s in t h e h o u s i n g . F o r t h e d r i v e a n d d r i v v e n g e a r b e a r i n g c u p s , u s e J – 3 8 5 6 8 - 1 D r i v e / D r i v e n B e a r i n g C u p I n s t a l l e r a n d J – 3 5 9 2 1 - 1 O u t p u t B e a r i n g I n s t a l l e r / D r i v e S le e v e . F o r t h e id l e r g e a r b e a r in g c u p , u s e J – 3 8 5 6 8 - 2 I d l e r B e a r in g C u p I n s t a l le r a n d J – 8 0 9 2 D r iv e H a n d l e . 3 1 . R e m o v e t h e t w o lu b e p a s s a g e p lu g s ( 3 3 ) ( F o ld o u t 1 3 ) . R e m o v in g t h e lu b e p lu g s p r o v i d e s a c c e s s t o o r ifi c e p l u g s ( 3 4 ) . 3 2 . R e m o v e t w o o r ifi c e p l u g s ( 3 4 ) . I n s p e c t t h e lu b e o r ifi c e s f o r o b s t r u c t io n s a n d r e m o v e a n y o b s t r u c t i o n s t h a t a r e f o u n d . 3 3 . In s ta ll o p lu g s ( 3 N ∙m (9 – to 2 4 – 2

r ifi c e p lu g 3 ). T ig h te 1 0 lb ft ) . 9 N ∙m (1 8

3 4 . R e m a n d o b s a re

lu b e p a s s a g e p lu g ( 2 5 ) ( F o l d o u t 1 4 ) c e p l u g ( 2 6 ) . I n s p e c t l u b e o r i fi c e f o r i o n s a n d r e m o v e a a n y o b s t r u c t i o n s t h a t d .

o v e o r ifi tru c t fo u n

s (3 n th T ig h – 2 1

4 ) e te lb

, a n d lu b e p a s s a g e o r ifi c e p l u g s t o 1 2 – 1 4 n lu b e p a s s a g e p l u g s f t ) .

3 5 . I n s t a l l o r ifi c e p l u g ( 2 6 ) a n d t ig h t e n t o 1 2 – 1 4 N ∙ m ( 9 – 1 0 l b f t ) . I n s t a l l l u b e p a s s a g e p l u g ( 2 5 ) a n d t ig h t e n t o 2 4 – 2 9 N ∙ m ( 1 8 – 2 1 lb f t ) .


M O D U L E b .

R E B U IL D

D i s a s s e m b l y o f C 6 C l u t c h ( F o l d o u t 1 4 ) .

1 1 . I n s p e c t t h r u s t b e a r in g ( 8 ) f o r w e a r a n d d a m a g e . I f d a m a g e d , r e m o v e t h r u s t b e a r in g ( 8 ) f r o m t h e C 6 h o u s in g .

1 . R e m o v e r e t a in in g r in g ( 6 ) ( 2 4 4 .5 m m O D ) h o l d i n g C 6 c lu t c h p l a t e s ( 1 0 ) a n d ( 1 1 ) a n d C 6 c lu t c h h u b ( 7 ) in t h e C 6 c lu t c h h o u s in g . 2 . R e m w it h c lu tc (9 ) . in t h h u b h u b

o v e C 6 c l u t c h h u b ( 7 ) b y l i f t i n g i t o u t a l o n g fi v e C 6 c l u t c h f r i c t i o n p l a t e s ( 1 0 ) , f o u r C 6 h s t e e l r e a c t i o n p l a t e s ( 1 1 ) , a n d b a c k p l a t e O n e s t e e l r e a c t i o n p l a t e ( 1 1 ) w i l l r e m a i n e C 6 c l u t c h h o u s i n g ( 1 9 ) . I n s p e c t c l u t c h s p li n e s f o r w e a r a n d d a m a g e . R e p l a c e ( 7 ) if i t i s d a m a g e d .

4 . S e p a r a t e b a c k p l a t e ( 9 ) , fi v e f r i c t i o n p l a t e s ( 1 0 ) , a n d fi v e r e a c t io n p l a t e s ( 1 1 ) .

7 . In s p e fl a tn e m in im m a x im

c t b a c s s , a n u m th u m c

k p la d th ic k n o n e

te (9 ) fo e fo l lo w e s s 7 .9 0 .4 0 m

r b u in g m m m (0

is to n l a n ) fo r o v e

s p r in g d c h e c w e a r, s p r in g

e a r , n s : ( 0 . 0 9 3 m c a t i o n s

o v e o r e s o t h e r s e m b l y

1 0 . R e m o v e p i s t o n ( 1 4 ) b y fi r m ly s t r i k in g t h e h o u s in g a g a i n s t a fl a t s u r f a c e . R e m o v e s e a lr in g s ( 1 5 ) a n d ( 1 6 ) f r o m p i s t o n ( 1 4 ) .

C o p y r ig h t ©

2 0 0 9

re m o v u s in g a r in g th e p r

4 . In s p d a m c lo t h c a n n

r r s , w e a r , d a m a g e , s p e c i fi c a t io n s : ( 0 . 3 1 1 in c h ) , a n d .0 1 6 in c h ) .

fo r c e , re m k s e a lr in g b n ic k s , a n d r e ta in e r a s

tc h h o u s e g a u g e a x im u m c h ) . If C n o r d a m g .

in g b a n d a llo w 6 c lu a g e d

u s a n a b tc h , r

h in g ( 2 1 ) o u t s id e le I D is h o u s i n g e m o v e it

A s s e m b l y o f C 6 C l u t c h ( F o l d o u t 1 4 ) .

3 . If h o b e in

8 . R e m o v e r e t a i n i n g r i n g ( 1 2 ) a f t e r u s i n g J – 3 8 5 7 3 C 6 S p r in g C o m p r e s s o r t o c o m p r e s s t h e C 6 p i s t o n s p r in g r e t a i n e r a s s e m b l y ( 1 3 ) . 9 . R e le a s e th e p th e s p e c ia l to o in h o u s in g ( 1 9 d a m a g e . R e m ( 1 3 ) .

C 6 c lu le s c o p T h e m . 4 2 4 i n is w o r h o u s in

2 . I f r e m o v e d , i n s t a l l C 6 c lu t c h h o u s i n g b u s h i n g ( 2 1 ) u s in g J – 3 8 5 6 9 P 3 C a r r i e r / C 6 / C 7 H o u s i n g B u s h i n g I n s t a l l e r a n d J – 8 0 9 2 D r iv e H a n d l e .

5 . V i s u a l l y i n s p e c t t h e f r i c t i o n p l a t e s ( 1 0 ) f o r d a m a g e o r e x c e s s iv e w e a r . I f a p la t e h a s p e r c e i v a b l e w e a r o r d i s t o r t i o n , m e a s u r e f o r s t e p w e a r o f f r i c t i o n p l a t e ( 1 0 ) , m a x i m u m a l lo w a b l e s t e p w e a r f o r r e u s e is 0 . 1 3 m m ( 0 . 0 0 5 i n c h ) . M e a s u r e t h e c o n e o f f r i c t i o n p l a t e s ( 1 0 ) . M a x im u m a l l o w a b l e c o n e o f f r i c t io n p l a t e f o r r e u s e is 0 . 4 m m ( 0 . 0 1 6 in c h ) . I f r e p l a c e m e n t i s n e c e s s a r y , r e m o v e t h e f r i c t i o n p l a t e s b y g e n t l y p r y i n g t h e m f r o m t h e b a c k p l a t e . ) fo r w ifi c a tio 6 m m 0 .4 0 m s p e c ifi

c .

th e a te te r. m (1 (2 1 ) C 6

1 . I n s p e c t C 6 c lu t c h h o u s in g ( 1 9 ) f o r g r o o v e w e a r . M a x im u m a l l o w a b l e g r o o v e w e a r f o r r e u s e is 2 . 2 9 m m ( 0 . 0 9 0 in c h ) .

3 . R e m o v e t h e r e m a i n i n g s t e e l r e a c t io n p l a t e ( 1 1 ) f r o m t h e C 6 c lu t c h h o u s in g ( 1 9 ) .

6 . I n s p e c t s te e l r e a c tio n p la t e s ( 1 1 d a m a g e , a n d th e fo llo w in g s p e c m in im u m t h ic k n e s s a llo w e d : 2 . 3 i n c h ) , m a x im u m a l l o w a b l e c o n e ( 0 . 0 1 6 in c h ) ; if a n y o f th e a b o v e a r e n o t m e t , r e p la c e t h e p a r t .

1 2 . M e a s u re b y u s in g m ic r o m e 3 6 .1 8 m b u s h in g fro m th e

e d , in s s le e v e h e lp m o p e r d

ta ll . M a k e ir e c

th r u s a c h in s u re t io n .

t b e e d th e S e e

a r in ta n g b e a F ig

g (8 s o r in g u re

) o v e r C 6 n t h e t h r u s t i s i n s t a l l e d 3 – 4 .

e c t p i s t o n ( 1 4 ) f o r s e a l r i n g g r o o v e a g e . C o r r e c t t h e d a m a g e w it h c r o c u s o r s o f t s t o n e . R e p la c e t h e p a r t i f d a m a g e o t b e c o r r e c t e d .

C A U T I O N : I n c o r r e c t l i p - t y p e s e a l r i n g i n s t a l l a t i o n c a n c a u s e i m p r o p e r t r a n s m i s s i o n o p e r a t i o n o r f a i l u r e . 5 . In s ta ll a s e a lr in g s e a lr in g in t e r n a l c lu t c h h p i s t o n .

n e (1 (1 a n o u

w e x 6 ) in 6 ), u d e x s in g

te rn a l s e a p is to n (1 s e p r o p e r te rn a l s e a (1 9 ), a n d

lr in 4 ). lip lr in th e

g ( 1 5 ) a n d i n t e r n a l F o r in t e r n a l p o s i t i o n . L u b e g b o r e s i n t h e C 6 s e a l r in g s o n t h e

N O T E : D E X R O N ® V I fl u i d s a r e n o t a p p r o v e d b y A l l is o n T r a n s m is s io n f o r u s e i n t h e 3 7 0 0 S P m o d e l t r a n s m is s io n . 6 . I n s t a l l p i s t o n ( 1 4 ) i n t o C 6 c l u t c h h o u s i n g ( 1 9 ) u s i n g a s o f t f a c e m a l le t t o s e a t t h e p i s t o n . 7 . In s p e c m is s in 7 . W E s p r in g a s s e m

t s p r in g r e t g o r b ro k e n A R L IM IT S s p e c ifi c a tio b ly ( 1 3 ) if s


a in e r s p r in A N D n s . R p e c ifi

a s s e g s . S P R e p la c a t io

m b ly (1 R e fe r to IN G D A c e s p r in n s a re n

3 ) f o r S e c t i o n T A fo r th e g r e t a i n e r o t m e t .

5 - 5 1

S E R V IC E


8 . I n s t a l l s p r i n g r e t a i n e r a s s e m b l y ( 1 3 ) . 9 . In s ta J – 3 8 s p r in s p e c

ll 5 g ia

re ta 7 3 -1 re ta l to o

i n i n g r i n g ( 1 2 ) a f t e r u s i n g a n d J – 3 8 5 7 3 - 3 t o c o m p r e s s t h e i n e r a s s e m b l y ( 1 3 ) . R e m o v e l s .

1 0 . I n s t a l l C 6 c lu t c h h u b ( 7 ) in t o t h e C 6 h o u s i n g . 1 1 . In s p la p la (1 0

t a l l fi v e r e a c t i o n p l a t e s ( 1 1 ) , a n d fi v e f r i c t i o n t e s ( 1 0 ) a l t e r n a t e l y , s t a r t i n g w i t h a r e a c t i o n t e ( 1 1 ) , a n d fi n i s h i n g w i t h a f r i c t i o n p l a t e ) .

N O in in a s



1 2 . I n s t a l l b a c k p l a t e ( 9 ) . 1 3 . I n s t a l l r e t a i n i n g r i n g ( 6 ) . d .

D i s a s s e m b l y o f C 7 C l u t c h ( F o l d o u t 1 3 ) . 1 . R e m o v e r e t a i n i n g r in g ( 6 0 ) . 2 . R e m C 7 c o f a a n d a lte r

o v e t h e C 7 c lu t c h lu t c h p a c k . T h e C b a c k p la t e ( 6 1 ) , fi v fi v e s te e l r e a c tio n n a t i n g o r d e r .

3 . In s p e a llo w m in im (0 .0 0 0 .2 5

c t C 7 fr ic tio n a b le th ic k n e s u m o il g r o o v 8 in c h ) , a n d m m m ( 0 .0 1 0 in

4 . In s p e a llo w (0 .0 8 p e rm

c t C a b le 3 in itt e d

7 re th ic c h ), fo r

a c t io n k n e s s m a x im re u s e

h u b 7 c lu e fr ic p la te

(5 tc t io s

9 ) a lo n g h p a c k c n p la te s (6 3 ) s ta c

p la te s (6 2 ) s — 2 .0 6 m m e d e p th a llo a x im u m c o c h ) . p la fo r u m is 0

te s (6 3 re u s e a llo w a .2 5 m m

fo r (0 w e n e

w it h o n s is t s ( 6 2 ) , k e d i n

m i n i m u m . 0 8 1 in c h ) , d — 0 . 2 0 m m p e r m it t e d —

) . M in is 2 . 1 1 b le c o (0 .0 1

i m u m m m n e 0 in c h ) .

5 . I n s p e c t b a c k p l a t e ( 6 1 ) f o r w e a r , fl a t n e s s , a n d d a m a g e . M in im u m a llo w a b l e t h ic k n e s s f o r r e u s e is 8 . 6 7 m m ( 0 . 3 4 1 in c h ) . 6 . R e m o v e C 7 p is to n ( 6 4 ) . R e m o v e in t e r n a l a n d e x t e r n a l s e a l r i n g s ( 6 6 ) a n d ( 6 5 ) f r o m p i s t o n ( 6 4 ) . 7 . M a m (

5 - 5 2

e a n d a x 1 .8

s u re im 6 1

8 . I n s p e c t p r e s s u r e r e l i e f b a l l ( 6 9 ) a n d m a k e s u r e t h e b a ll m o v e s f r e e l y ; m i n i m u m r e q u i r e d m o v e m e n t is 1 . 0 0 m m ( 0 . 0 4 0 in c h ) .

r e t h e C 7 c lu t c h h o u s in g b u s h in g I D p l a c e b u s h i n g ( 6 8 ) i f r e q u i r e d . T h e u m a llo w a b le I D f o r r e u s e is 4 7 . 2 6 m m i n c h ) .

C o p y r ig h t ©

9 . R e m o v e t h r e e s e a lr in g s ( 7 0 ) f r o m h o u s i n g ( 6 7 ) . e .

C 7 c lu t c h

A s s e m b l y o f C 7 C l u t c h H o u s i n g ( F o l d o u t 1 3 ) . 1 . In s p e c s e a lr in h o u s in h o u s in

t C 7 c lu g g ro o v g s p lin e g if it i s

tc h e a n w e d a m

2 . In s ta ll th r e e n e w h o u s i n g ( 6 7 ) . 3 . If b u s h b u s h in H o u s in H a n d le

h o d a r a

u s in g ( 6 7 ) f o r d a m a g e t o p i s t o n s e a l s u r f a c e s , a n d . R e p l a c e t h e C 7 c lu t c h g e d .

s e a l r i n g s ( 7 0 ) i n t o C 7 c l u t c h

i n g ( 6 8 ) w a s r e m o v e d , i n s t a l l t h e g u s i n g J – 3 8 5 6 9 P 3 C a r r ie r / C 6 / C 7 g B u s h i n g I n s t a l le r a n d J – 8 0 9 2 D r iv e .

4 . I n s t a l l p r e s s u r e r e l i e f b a l l ( 6 9 ) i f i t w a s r e m o v e d . M a k e s u r e t h a t it m o v e s f r e e l y . 5 . I n s p e c t p i s t o n ( 6 4 ) f o r s e a l r i n g g r o o v e d a m a g e a n d b u r r s . C A U T I O N : I n c o r r e c t l i p - t y p e s e a l r i n g i n s t a l l a t i o n c a n c a u s e i m p r o p e r t r a n s m i s s i o n o p e r a t i o n o r f a i l u r e . 6 . In s ta p is to p ro p o n th h o u s

ll n e w s e a n (6 4 ). B e e r ly p o s it io e p is to n , a i n g ( 6 7 ) .

lr in g s u r n e d n d s

s (6 e th . L u e a l

5 ) a t b e b o

a n s e th re

d (6 a lr in e s e a re a

6 ) in g lip a lr in s in

t o C 7 s a r e g a r e a s C 7 c lu t c h

N O T E : D E X R O N ® V I fl u i d s a r e n o t a p p r o v e d b y A l l is o n T r a n s m is s io n f o r u s e i n t h e 3 7 0 0 S P m o d e l t r a n s m i s s io n . 7 . I n s t a l l p i s t o n ( 6 4 ) in t o C 7 c lu t c h h o u s i n g ( 6 7 ) . B e s u r e it i s p r o p e r ly s e a t e d . 8 . In s p a n d re p a c lu t c

e c d a ira h

t C 7 m a g b le . h o u s

9 . In s t a ll fi v e p la te s ( 6 3 o r d e r, s ta r fi n is h in g w

c lu e . In s in g

f r ic ) in t in g ith


tc h R e p ta ll (6 7

t io to w a

h u b ( 5 9 ) s p lin e s f o r w e a r la c e h u b if d a m a g e is n o t C 7 c l u t c h h u b ( 5 9 ) i n t o C 7 ) .

n p h o u ith fr ic t

la s a io

te s in g re a n p

(6 2 ) (6 7 ) c t io n la t e (

a n d fi v e r e a c t i o n i n a l t e r n a t i n g p l a t e ( 6 3 ) a n d 6 2 ) .

M O D U L E

N O in in a s


9 . I n s t a l l p r e s s u r e r e l i e f v a l v e ( 6 ) , a n d s p r i n g ( 7 ) in t o b o r e in t h e p u m p h o u s in g .


1 0 . I n s t a l l a n e w w a s h e r o n t o p l u g ( 8 ) , t h e n in s t a l l t h e p lu g a n d t ig h t e n it t o 1 2 – 1 4 N ∙ m ( 9 – 1 0 lb f t ) .

1 0 . I n s t a l l b a c k p l a t e ( 6 1 ) i n t o C 7 c l u t c h h o u s i n g ( 6 7 ) . 1 1 . In s ta ll re ta in in g h o u s i n g ( 6 7 ) . f.

R E B U IL D

r in g

h .

1 . R e m o v e P 4 s u n g e a r ( 6 3 ) b y lif t in g it o u t o f t h e P 4 c a r r ie r a s s e m b l y ( 5 6 ) .

( 6 0 ) i n t o C 7 c l u t c h

2 . R e m o v e o n e s e t s c re w w r e n c h o r s o c k e t.

D i s a s s e m b l y o f O il P u m p ( F o l d o u t 1 3 ) .

( 5 8 ) b y u s in g a n A lle n

1 . R e m o v e p r e s s u r e r e l ie f v a lv e p l u g ( 8 ) .

3 . P u s h s p in d l e ( 5 9 ) o u t f r o m

2 . R e m o v e s p r in g ( 7 ) , a n d t h e n r e m o v e p r e s s u r e r e l i e f v a l v e ( 6 ) .

4 . R e m o v e p in io n g e a r ( 6 1 ) , a l o n g w it h u p p e r a n d lo w e r t h r u s t w a s h e r s ( 6 2 ) , a n d u n c a g e d n e e d l e b e a r in g s ( 6 0 ) .

3 . R e m o v e lo c a t in g p i n s ( 9 ) f r o m f r o n t c o v e r ( 8 3 ) b y d r i v in g t h e m o u t u s in g a s m a l l p u n c h a n d a h a m m e r. 4 . S e p a r a te fro n t c o v e r (8 3 ) fro m p u m p a s s e m b ly . 5 . R e m th e n r in g d r iv e g .

D i s a s s e m b l y o f P 4 C a r r i e r ( F o l d o u t 1 4 ) .

o v e d re m o (8 6 ). n g e a

t h e r e s t o f t h e

2 . U s in g a n o u t s id e m ic r o m e t e r , m e a s u r e t h e d r iv e n g e a r w id t h a n d t h e d r iv e g e a r w id t h . in e c tin g d e p t m m

e a c th e h . T (0 .0

h g g e h e 0 5

e a r a r w s p e in c h

i.

A s s e m b l y o f P 4 C a r r i e r ( F o l d o u t 1 4 ) .

2 . I n s p e c t t h r e e u p p e r a n d t h r e e lo w e r t h r u s t w a s h e r s ( 6 2 ) f o r w e a r a n d d a m a g e .

1 . U s e a d e p th g a u g e t o m e a s u r e p u m p c a v it y d e p t h in p u m p r e a r c o v e r ( 8 7 ) .

e te rm u b tra a v ity .1 2 5

5 . R e p e a t S t e p s 2 t h r o u g h 4 t o r e m o v e t h e r e m a i n i n g t w o p i n i o n g e a r s ( 6 1 ) .

1 . I n s p e c t t h r u s t s u r f a c e s o n e a c h o f t h r e e p i n i o n g e a r s ( 6 1 ) f o r w e a r a n d d a m a g e . A ls o in s p e c t in s id e b o r e a n d g e a r t o o t h a r e a s .

r i v e g e a r ( 8 4 ) f r o m h o u s in g ( 8 7 ) , v e d r iv e n g e a r ( 8 5 ) a n d r e v e r s in g N o t e t h e o r i e n t a t i o n o f d r i v e a n d r s .

A s s e m b l y o f O i l P u m p ( F o l d o u t 1 3 ) .

3 . D s c 0

t h e P 4 c a r r ie r .

s id e c le a r a n c e b y id t h f r o m t h e p u m p c i fi e d s id e c le a r a n c e i s ) .

4 . I f n o t w i t h i n t h e s p e c i fi c a t i o n , r e p l a c e c o m p o n e n t s a s r e q u i r e d .

3 . In s e a E a in d h o

ta ll th r e c h o f th c h w a s e x e s w u s i n g .

4 . A p in s b e U s b e

p ly id e a r in e th a r in

e lo w re e p h e r h it h th

a g e n e r b o re o f g s (6 0 ) e s p in d g s a re p

e r in io a s e n

o u e a in t le r o

th r u s n s lo a m a o tc h

t w ts c h in

s a m o u n t c h p in io n o e a c h o f to m a k e s p e r ly a l ig n

a in in th

s h P e d e

e rs (6 4 c a rr ta n g P 4 c a

o f lu b g e a r. th r e e u re th e d .

2 ) ie r w h r r ie

r ic a n In s ta p in io e n e

i n t o ( 5 7 ) . ic h r

t t o t h e l l n e e d l e n s ( 6 1 ) . e d le

5 . I n s t a l l r e v e r s i n g g e a r ( 8 6 ) .

5 . I n s t a l l p i n i o n ( 6 1 ) a n d n e e d l e b e a r in g ( 6 0 ) a s s e m b l y i n t o P 4 c a r r i e r ( 5 7 ) w i t h l o w e r t h r u s t w a s h e r ( 6 2 ) a l r e a d y in p l a c e .

6 . I n s t a l l d r iv e n a n d d r iv e g e a r s ( 8 5 ) a n d ( 8 4 ) i n t h e s a m e o r ie n t a t io n a s t h e y w e r e r e m o v e d t o m a t c h w e a r p a t t e r n in r e a r p u m p c o v e r ( 8 7 ) .

6 . I n s t a l l u p p e r t h r u s t w a s h e r ( 6 2 ) , a l i g n i n g t h e w a s h e r in d e x i n g t a b w it h t h e n o t c h in P 4 c a r r i e r ( 5 7 ) .

7 . T h e g r o o v e i n r e v e r s i n g r i n g ( 8 6 ) i n d e x e s w i t h t h e n o t c h in t h e p u m p f r o n t c o v e r ( 8 3 ) .

7 . I n s p e c t s p in d le ( 5 9 ) f o r w e a r a n d d a m a g e . M a k e s u r e t h e fl u id h o le s a r e f r e e o f o b s t r u c t i o n s .

8 . In s ta ll p u m h o le s w ith D r iv e lo c a b a c k o f th t o s lig h t ly

p fro n t c o v e th e lo c a t in g tin g p in s ( 9 ) e p u m p h o u s c o u n t e r s i n n k

r ( 8 3 ) , a lig p in s in h o in t o t h e c o in g . U s e a t h e p i n s .

n in g u s in g v e r fr s m a

C o p y r ig h t ©

t h e ( 8 7 ) . o m t h e ll p u n c h 2 0 0 9

8 . I n s t a l l s p i n d l e ( 5 9 ) i n t o P 4 c a r r i e r ( 5 7 ) , a l i g n i n g t h e s e t s c r e w p i l o t o n t h e s p i n d l e w i t h t h e h o l e in t h e h o u s i n g .


5 - 5 3

S E R V IC E


9 . I n s t a l l o n e o f t h r e e s e t s c r e w s ( 5 8 ) , a n d t i g h t e n t o 2 5 – 3 5 N ∙ m ( 1 8 – 2 6 l b f t ) . U s in g a c h is e l a n d a h a m m e r , s w a g e s e t s c r e w b o r e . 1 0 . R e p e a t S t e p s 6 t h r o u g h 9 t o in s t a l l t h e r e m a i n i n g t w o p i n i o n g e a r s ( 6 1 ) . 1 1 . I n s t a l l s u n g e a r ( 6 3 ) in t o P 4 c a r r ie r a s s e m b l y ( 5 7 ) . j . D i s a s s e m b l y o f D r i v e , I d l e r , a n d D r i v e n G e a r s ( F o l d o u t 1 3 ) . 1 . In s p e c t b a n d (8 1 ) In s p e c t in a n d (2 0 ) (3 8 ) a n d b e a r in g s (8 0 ) re q u in th e n e 2 . T o r (1 9 ) th e fi x tu th e

e a r in g s ( 1 8 ) , ( 2 0 ) , ( 3 8 ) , ( 4 0 ) , ( p e r g u id e lin e s e x p la in e d in 3 – g B e a r in g s . If a n y o f b e a r in g s in s t a lle d o n d r iv e g e a r ( 1 9 ) , b e ( 4 0 ) in s t a lle d o n id le r g e a r ( 3 9 ( 7 9 ) a n d ( 8 1 ) in s t a lle d o n d r iv e ir e r e p la c e m e n t, u s e th e p r o c e x t s t e p .

e m o v e b , in s t a ll a b e a r in g . re (s ), re m g e a r .

e a r in la r g U s in o v e

g (1 e s p g a p th e

8 ) f r o m d r iv lit b e a r in g p p r o p r ia t e t o b e a r i n g b y

7 9 ) , 5 e . ( 1 8 ) a r i n g s ) , o r n g e a r d u r e

e g e a r u l l e r o n o l ( s ) a n d p r e s s in g o u t

3 . T o r e m o v e b e a r i n g s ( 2 0 ) , ( 3 8 ) , ( 4 0 ) , ( 7 9 ) , o r ( 8 1 ) , f o l l o w t h e p r o c e d u r e i n S t e p 2 . k . A s s e m b l y o f D r i v e , I d l e r , a n d D r i v e n G e a r s ( F o l d o u t 1 3 ) . 1 . In s p e c d r iv e n R e fe r in s p e c

t d g e to t io

2 . If re m o v g e a r (1 9 B e a r in g p ro c e d u (1 9 ), o r ( 8 0 ) . 3 . If (3 Id R (4

re m 9 ) le r e p e 0 )

r iv e g e a r a r (8 0 ) fo 3 – 5 i. In s n g u id e lin

( 1 9 ) , i d l e r g e a r ( 3 9 ) , a n d r t o o t h w e a r a n d d a m a g e . p e c t in g G e a r s f o r g e a r e s .

e d , in s t a ll b e a r in g ) u s in g J – 3 8 5 7 9 In s t a lle r a n d p r e s r e to in s t a ll b e a r in b e a r in g s ( 7 9 ) a n d

o v e d , i n s t a l l b e a r i n u s in g J – 3 8 5 7 9 - 2 F w B e a r in g In s t a lle r a n a t th e s a m e p r o c e d o n i d l e r g e a r ( ( 3 9 ) .

(1 8 ) o n 1 D r iv e / D s . R e p e a g (2 0 ) o n (8 1 ) o n d

g (3 d /R d a p u re

8 ) e a p r to

d r iv r iv e t th e d r iv r iv e

e n s a m e e g e a r n g e a r

o n i d d l e r O u tp u o p r ia t e in s t a ll b

r g e a r t a n d p r e s s . e a r in g

l. D i s a s s e m b l y o f t h e F r o n t O u t p u t H o u s in g a n d F r o n t O u t p u t S h a f t ( F o l d o u t 1 3 ) . 1 . R e m o v e f r o n t o u t p u t s h a f t n u t ( 4 2 ) a n d fl a t w a s h e r ( 4 3 ) . 5 - 5 4

C o p y r ig h t ©

2 . P r e s s f r o n t o u t p u t s h a f t ( 5 7 ) o u t o f f r o n t o u t p u t y o k e ( 4 4 ) . 3 . R a J b

e m n d a w o re

o v e o u t p u t s e a l ( 4 6 ) b y u s in g a h a m m e r a c h is e l o r J – 2 4 1 7 1 - A S lid e H a m m e r a n d S e t. B e c a r e fu l n o t t o d a m a g e t h e s e a l a r e a .

4 . R e m o v e o u t p u t s h a f t b e a r in g ( 4 7 ) . 5 . In s p e c t b e a r in s c o r in g , a n d d n e e d s r e p la c e a n d a d r if t o r a R a c e R e m o v e

g c u p s a m a g e m e n t, r h a m m r.

(4 8 ) a n . If th e e m o v e e r a n d

d (5 b e a it u s J – 3

5 ) r in in g 9 4

fo r g c a 0 B

p i t t in g , u p ( s ) h a m m e r e a r in g

6 . R e m o v e s h im s ( 5 1 ) , ( 5 2 ) , o r ( 5 3 ) , a n d o u t p u t b e a r in g s p a c e r ( 5 4 ) f r o m o u t p u t s h a f t ( 5 7 ) . 7 . If b e a r in re m o v e in s t a ll a a n d p o s p r e s s ta a n a p p r

g (5 6 ) o n o u tp u b e a r in g ( 5 6 ) . T s p lit b e a r in g p it io n th e b e a r in b le . P r e s s th e o p r ia t e p r e s s .

t s h a ft (5 o re m o v u lle r o n g a n d th o u tp u t s

7 ) is d a m e b e a r in th e b e a r e p u lle r h a ft o u t

a g e d , g ( 5 6 ) , i n g , o n a u s i n g

m . A s s e m b l y o f t h e F r o n t O u t p u t H o u s in g a n d F r o n t O u t p u t S h a f t ( F o l d o u t 1 3 ) . 1 . I n s p e c t o u t p u t h o u s i n g ( 4 9 ) f o r s c o r i n g a n d b u r r s 2 . If r e m o v e d , in s ta ll n e w a n d ( 5 5 ) . T o in s t a ll t h e J – 3 8 5 6 8 -3 F w d /R e a r O In s t a lle r a n d a p r e s s . P u n t il it b o t to m s in t h e o u

b e a r in g c b e a r in g c u tp u t B e a r e s s e a c h tp u t h o u s

u p s ( 4 8 ) u p s , u s e r in g C u p b e a r i n g c u p in g ( 4 9 ) .

3 . P o s i t io n b e a r in g ( 4 7 ) in o u t p u t h o u s i n g ( 4 9 ) . 4 . In u In B

s ta ll o u tp s in g J – 3 s ta lle r ( M e a r in g I n

u t 8 5 D s ta

s e 4 7 3 0 lle

a l F r 7 0 r/D

5 . In s p e c t o u tp u t y o k s u r fa c e . M in im u m d ia m e te r fo r r e u s e If th e y o k e d o e s n s p e c ifi c a tio n , r e p la

(4 6 o n ) a r iv

) in t A n n d e S

th e d R J – 3 le e v

e (4 4 ) fo a llo w a b is 7 6 . 2 0 o t m e e t c e th e y

o u t p u t h o u s i n g e a r O u tp u t S e a l 5 9 2 1 - 1 O u t p u t e .

r s c o r in le s e a l m m (3 th e re q o k e .

g o f s e a l s u r f a c e . 0 0 in c h ) . u ir e d

6 . I n s p e c t o u t p u t s h a f t ( 5 7 ) f o r s p l i n e d a m a g e a n d s c o r i n g . I f n e c e s s a r y , r e p l a c e t h e o u t p u t s h a f t . 7 . If re s h a J – 3 B e a

m o v e d , ft (5 7 ). 8 5 7 9 -2 r in g In s

in s t a ll b e a r in T o in s t a ll th e F w d /R e a r O u ta l le r . P o s itio


g (5 6 ) b e a r in tp u t a n n th e b

o n g , d e a

o u t p u t u s e I d le r r i n g a n d

M O D U L E J – 3 8 5 7 9 -2 I n s t a l le r o n p r e s s th e o u n til it is fu

F w d th e u tp u lly s e

/ R e a r O u t p u t a n d I d l e r B e a r in g p r e s s t a b l e , a n d t h e n c a r e f u l l y t s h a f t ( 5 7 ) i n t o t h e b e a r i n g a t e d .

8 . P la c e f r o n t y o k e a s s e m b ly ( 4 4 ) o n a p r e s s t a b l e . 9 . P o s it io n o u t p u t h o u s i n g ( 4 9 ) o n t h e y o k e . 1 0 . P la c e b e a r in g s p a c e r ( 5 4 ) a n d s h im s ( 5 1 ) , ( 5 2 ) , o r ( 5 3 ) o n o u t p u t s h a f t ( 5 7 ) ; t h e n u m b e r o f s h im s c o u ld b e o n e o r m o r e . 1 1 . In s ta ll h o u s in s e a l (4 c o m p o o u tp u t d u r in g re la te d

o u t p u t s h a ft ( 5 7 ) in g (4 9 ) th ro u g h b e a 6 ) , a n d in t o y o k e ( n e n t s a r e p r o p e r ly s h a ft (5 7 ). R o ta te th is p r o c e d u re to h c o m p o n e n ts s e a t

t o f r o n t o u t p u t r in g ( 4 7 ) , o u t p u t 4 4 ) . O n c e a l l t h e a l i g n e d , p r e s s f r o n t o u t p u t h o u s i n g ( 4 9 ) e l p t h e s h a f t a n d i t s p r o p e r ly .

1 2 . I n s t a l l fl a t w a s h e r ( 4 3 ) a n d f r o n t o u t p u t s h a f t n u t ( 4 2 ) . 1 3 . P e r e x p P re th e

fo rm la in e lo a d re a r

th e b e d in 5 – P ro c e d o u tp u t

a r in 1 6 p u re h o u

g p . O (F s in

r e lo a u tp u o ld o u g a s

d p ro t H o u t 1 4 ) a n e x

c e d u s in g w h ic a m p

r e a s B e a r in g h u s e s le .

n . D i s a s s e m b l y o f t h e R e a r O u t p u t H o u s in g ( F o l d o u t 1 4 ) . 1 . R e m o v e r e t a i n i n g r in g ( 6 4 ) t o r e m o v e P 4 r in g g e a r ( 6 5 ) . 2 . R e m o v e P 4 r i n g g e a r ( 6 5 ) f r o m h o u s i n g ( 7 4 ) .

6 . R e m o v e o u tp u t s e a l ( 7 8 ) b y u s in g J – 2 4 1 7 1 - A S l id e H a m m e r a n d J a w S e t . B e c a r e f u l n o t t o d a m a g e t h e s e a l b o r e a r e a s . 7 . R e m o v e o u t p u t s h a f t b e a r in g ( 7 7 ) if it is d a m a g e d . a n h e e e R a

d ( b e a c c e

u tp u t s h a ft (6 6 r e m o v e b e a r in th e p r e s s ta b le r. U s in g a p r e a f t ( 6 6 ) .

) i s g ( 6 7 ) , a n d s s ,

o . A s s e m b l y o f t h e R e a r O u t p u t H o u s i n g ( F o l d o u t 1 4 ) . 1 . I n s p e c t o u t p u t h o u s i n g ( 7 4 ) f o r s c o r i n g a n d b u r r s . 2 . If (6 J – a n

r e m o v e d , i n s t a l l b e a r i n g c u p s ( 7 6 ) a n d 8 ) in t o r e a r o u t p u t h o u s i n g ( 7 4 ) b y u s i n g 3 9 4 0 B e a r in g R a c e R e m o v e r o r a h a m m e r d a d r if t .

3 . P o s i t io n b e a r in g ( 7 7 ) in t o t h e o u t p u t h o u s i n g . 4 . In s ta ll o u u s in g J – In s ta lle r B e a r in g L ip - T y p e

tp u t 3 8 5 4 (M D In s ta S e a

s e a l (7 8 7 F ro n t 3 0 7 0 ) a lle r /D r iv ls fo r s e

5 . In s p e c t o b u rrs , a n s u rfa c e ; is 7 6 .2 0 m e e t th e y o k e .

u tp u t y o k d d a m a g m in im u m m m (3 .0 0 re q u ire d

) in t o th e o u A n d R e a r O n d J – 3 5 9 2 1 e S le e v e . S a l lu b r ic a tio n

e (7 9 e . M a llo w in c h s p e c

) s e a l a e a s u re a b le s e ). If th e ifi c a t io n

tp u t u tp u -1 O e e 3 in fo

h o u s i n g t S e a l u t p u t – 6 g . r m a t i o n .

r e a f o r n i c k s , y o k e s e a l a l j o u r n a l O D y o k e d o e s n o t , r e p l a c e t h e

8 . I n s p e c t r e a r o u t p u t s h a f t ( 6 6 ) f o r s p l i n e d a m a g e a n d s c o r in g , a n d if r e q u i r e d , r e p la c e t h e r e a r o u t p u t s h a f t

5 . R e m o v e y o k e ( 7 9 ) . C h e c k y o k e s e a lin g a r e a f o r n i c k s , b u r r s , o r d a m a g e .

u p s (7 6 ) a g e . If t t, re m o v B e a r in g d r if t .

1 0 . If b e a r in g ( 6 7 ) o n r e a r o d a m a g e d , r e p la c e it. T o p o s it io n t h e b e a r in g o n in s t a ll s p lit b e a r in g p u lle p r e s s o u t r e a r o u tp u t s h

7 . P o s i t i o n o u t p u t h o u s i n g ( 7 4 ) o n t h e y o k e .

4 . R e m o v e r e a r o u t p u t s h a f t ( 6 6 ) b y p r e s s in g it o u t o f r e a r o u t p u t y o k e ( 7 9 ) .

b e a r in g c , a n d d a m p la c e m e n g J – 3 9 4 0 e r a n d a

9 . R e m o v e s h im s ( 7 0 ) , ( 7 1 ) , o r ( 7 2 ) , a n d b e a r in g s p a c e r ( 6 9 ) f r o m r e a r o u t p u t s h a f t ( 6 6 ) .

6 . P la c e o u t p u t y o k e ( 7 9 ) o n a p r e s s t a b le .

r e a r o u t p u t

3 . R e m o v e o u tp u t n u t ( 8 1 ) a n d w a s h e r ( 8 0 ) .

8 . In s p e c t s c o r in g n e e d re b y u s in a h a m m

R E B U IL D

6 8 ) f o r p i t t in g , a r i n g c u p s h b e a r in g c u p R e m o v e r o r

C o p y r ig h t ©

2 0 0 9

9 . I f r e m o v e d , in s t a l l n e w b e a r in g ( 6 7 ) o n r e a r o u t p u t s h a f t ( 6 6 ) . T o i n s t a l l b e a r in g ( 6 7 ) , u s e J – 3 8 5 7 9 - 2 . P o s it io n t h e b e a r in g a n d J – 3 8 5 7 9 - 2 F w d / R e a r O u t p u t a n d I d l e r B e a r i n g I n s t a l l e r o n t h e p r e s s t a b l e , a n d c a r e f u l l y p r e s s r e a r o u t p u t s h a f t ( 6 6 ) i n t o t h e b e a r i n g u n t i l i t i s f u l l y s e a t e d . 1 0 . I n s t a l l b e a r in g s p a c e r ( 6 9 ) a n d s h im s ( 7 0 ) , ( 7 1 ) , o r ( 7 2 ) o n t o r e a r o o u t p u t s h a f t ( 6 6 ) . 1 1 . P r a s a n h o

e s s e d u s

s re a r o u m b ly ( 7 9 o u tp u t s e in g (7 4 )


tp u t ) p a s a l (7 s p in s

s h a s in 8 ), fre

f t ( 6 6 ) i n t o r e a r y o k e g t h r o u g h b e a r i n g ( 7 7 ) m a k i n g s u r e t h e o u t p u t e l y .

5 - 5 5

S E R V IC E


1 2 . I n s t a l l w a s h e r ( 8 0 ) a n d o u t p u t s h a f t n u t ( 8 1 ) b u t d o n o t t ig h t e n . 1 3 . P la c e P 4 r in g g e a r ( 6 5 ) in o u t p u t h o u s i n g ( 7 4 ) . 1 4 . I n s t a l l r e t a i n i n g r i n g ( 6 4 ) . 1 5 . F o l lo w t h e b e a r in g p r e l o a d p r o c e d u r e e x p l a i n e d i n 5 – 1 6 p . O u t p u t H H o o u s i n g B e a r i n g P r e l o a d P r o c e d u r e ( F o l d o u t 1 4 ) . p . O u t p u t H o u s i n g B e a r i n g P r e lo a d P r o c e d u r e ( F o l d o u t 1 4 ) .

q . D i s a s s e m b l y o f C 7 C o n t r o l V a lv e B o d y ( F o l d o u t 1 4 ) . 1 . B e g i n C 7 c o n t r o l v a lv e b o d r e m o v in g p in s ( 3 4 ) a n d ( 4 0 s ig n a l v a lv e s o le n o i d ( 3 5 ) a in c o n t r o l v a lv e b o d y ( 3 0 ) . b y d r i v in g t h e m o u t f r o m t h b o t t o m ( m a c h i n e d f a c e ) .

y d is ) s e c n d C R e m e to p

a s s u r in 7 v o v e to w

e m b g th a lv e th e a rd

l y b y e C 7 ( 3 1 ) p i n s t h e

2 . R e m o v e s to p ( 3 3 ) , s p r in g ( 3 2 ) , a n d v a lv e ( 3 1 ) f r o m c o n t r o l v a l v e b o d y ( 3 0 ) .

1 . I n s t a l l o u t p u t h o u s i n g ( 7 4 ) o n t h e r e a r t r a n s f e r c a s e h a lf ( 2 ) .

3 . R e m o v e s o le n o id ( 3 5 ) a n d O - r i n g s ( 3 6 ) a n d ( 3 7 ) .

2 . R e m o v e o u t p u t s h a f t n u t ( 8 1 ) .

4 . R e m o v e s o le n o i d r e g u l a t o r v a lv e ( 3 8 ) .

3 . I n s t a l l w a s h e r ( 8 0 ) o n t h e o u t p u t s h a f t a f t e r c o a t in g b o t h s i d e s w it h s e a la n t .

5 . C h e c k t h e v a lv e s a n d b o r e s f o r w e a r , s c o r in g , a n d d a m a g e .

4 . L u b e t h e t h r e a d s o n t h e o u t p u t s h a f t . 5 . I n s t a l l o u t p u t s h a f t n u t ( 8 1 ) a n d t i g h t e n t o 6 1 0 – 8 1 5 N ∙ m ( 4 5 0 – 6 0 0 lb f t ) . 6 . I n s t a l l a d i a l i n d i c a t o r t o r e a d u p a n d d o w n s h a f t m o v e m e n t s . N O T E : Y o u m a y n e e d t o p l a c e a s h i m o r a s m o o t h w a s h e r o n t h e o u t p u t s h a f t t o g e t t r u e r e a d i n g s . 7 . B o t t o m t h e o u t p u t s h a f t b y a p p ly in g d o w n w a r d f o r c e w h i l e s l i g h t l y r o t a t i n g t h e o u t p u t y o k e . 8 . T h e s h a f t i s b o t t o m e d w h e n t h e d i a l i n d i c a t o r s h o w s n o m o r e d o w n m o v e m e n t . Z e r o t h e d i a l i n d i c a t o r a t t h i s p o i n t . 9 . U u o s

s in g a c p w a rd fo n th e o u lig h tly r o

h a in rc e tp u t ta te

h o o f 7 s h a th e

is t 3 4 ft. y o

a n – 7 W k e

d a s c a le , a p p ly a n 7 8 N ( 1 6 5 – 1 7 5 lb s ) h i l e f o r c e is a p p l ie d , .

1 0 . C h e c k t h e d i a l in d i c a t o r f o r m o v e m e n t . 1 1 . If th e in d ic a t o r s p e c ifi e d l i m i t s c h e c k p r e lo a d 0 .0 2 5 – 0 .1 2 7 m 1 2 . If t h e in d s p e c ifi e d ( 8 0 ) w ith R e p e a t S

5 - 5 6

ic a lim s e te

re a d in g s , a d d o r a g a in . E m (0 .0 0 1

to r r e a d in its , c o a t b a l a n t a n d p 5 fro m a

g s o t in b o

a r re m n d – 0

e n o o v e p la y .0 0 5

t w i t h i n t h e s h im s a n d m u s t b e in c h ) .

a r h s s ta v e

e w i t h i n t h e id e s o f t h e w a s h e r l l t h e w a s h e r . .

C o p y r ig h t ©

r . A s s e m b ly o f C 7 C o n t r o l V a lv e B o d y A s s e m b l y ( F o l d o u t 1 4 ) . 1 . I n s e r t s o l e n o i d r e g u l a t o r v a l v e ( 3 8 ) i n t h e b o r e o f b o d y ( 3 0 ) a n d in s p e c t f o r s m o o t h m o v e m e n t. 2 . I n s p e c t s o l e n o id fi lt e r s c r e e n f o r d a m a g e o r d e b r i s . 3 . R e p l a c e s o l e n o i d O - r i n g s ( 3 6 ) a n d ( 3 7 ) d u r i n g o v e r h a u l . 4 . I n s e r t s o l e n o i d ( 3 5 ) i n t o c o n t r o l v a l v e b o d y ( 3 0 ) . 5 . I n s e r t v a l v e ( 3 1 ) , f o l l o w e d b y s p r i n g ( 3 2 ) a n d s t o p ( 3 3 ) . 6 . P u s h a n d in th e to p a rts 7 . In s w h p in th e

in o n s e rt p h o in p o

s to p ( 3 3 ) t o c o m p r e s s s p r in g ( 3 2 ) a s m a l l c y l i n d r i c a l p u n c h t h r o u g h l e i n t h e b o d y ( 3 0 ) t o h o l d t h e s e s i t i o n .

t a ll p in ( 3 e re th e p in t o p o s p in is in

4 ) b y u n c h it io n . s t a lle

s t a r t i n g i t i n t h e h o l e o p p o s i t e h a s b e e n in s e r t e d . T a p t h e T h e p u n c h i s d i s p l a c e d a s d .

8 . In s ta l l p in ( 4 0 ) w h i c In s e rt th e s m o o th e m a t in g h o le a t t h e b T a p t h e p in in t o p o s o f b o d y (3 0 ). U s e a s lig h t ly c o u n te r s in k

2 0 0 9 A l l i s o n T r a n s m i s s i o n , I n n c .

h re ta in s n d o f th e o tto m fa c it io n fl u s h s m a ll d ia p i n ( 4 0 ) .

s o p e w m

l e n o i d ( 3 5 ) . in in t o t h e o f b o d y ( 3 0 ) . it h t h e b o t t o m e t e r p u n c h t o

M O D U L E s . A s s e m b ly o f T r a n s fe r C a s e M o d u le ( F o l d o u t 1 2 - 2 , F o l d o u t 1 3 , F o l d o u t 1 4 ) .

R E B U IL D 1 4 . I n s t a l l g u i d e p i n s t o f a c i l i t a t e t h e i n s t a l l a t i o n o f s h i m s ( 1 0 ) , ( 1 1 ) , a n d ( 1 2 ) ( F o l d o u t 1 4 ) .

1 . L u b e b e a r in g c u p s ( 1 7 ) , ( 3 7 ) , a n d ( 7 8 ) ( F o l d o u t 1 3 ) i n s t a l l e d i n f r o n t t r a n s f e r c a s e h o u s i n g ( 1 4 ) .

1 5 . I n s t a l l s h im s ( 1 0 ) , ( 1 1 ) , a n d ( 1 2 ) s h im p a c k A ; t h e r e m a y b e m o r e t h a n o r f e w e r t h a n t h r e e s h i m s .

2 . O n e s h o u (1 9 ) to w a

1 6 . In M to (3

s id ld e s o rd

e o f d r iv r th a n th t h e s id e th e fro n t

e g e e o th w ith o f th

a r (1 e r s th e e tra

9 id s n

) h e . h o r s m

a s In s te r is s

a s h o r t e r t a l l d r i v e g e a r s h o u ld e r i s io n .

s ta 1 0 th 8 –

ll lu b e c x 1 .5 x e c a s e . 4 5 lb ft )

h a r g i n g p u m p ( 5 ) a n d t h e e i g h t 3 5 b o lt s ( 4 ) s e c u r i n g t h e p u m p T i g h t e n b o l t s ( 4 ) t o 5 1 – 6 1 N ∙ m .

3 . I n s t a l l i d l e r g e a r ( 3 9 ) w i t h i t s t h r e a d e d h o l e t o w a r d t h e f r o n t o f t h e t r a n s m i s s io n .

1 7 . I n s t a l l g u i d e p i n s i n t o t h e t w o m a n i f o l d b o l t h o le s in t h e f r o n t t r a n s f e r c a s e h o u s i n g ( 1 4 ) .

4 . I n s t a l l d r i v e n g e a r ( 8 0 ) i n t o f r o n t t r a n s f e r c a s e h o u s in g ( 1 4 ) in t h e s a m e o r ie n t a t io n a s it w a s r e m o v e d .

1 8 . I n s t a l l m a n i f o l d s h i m s ( 7 5 ) , ( 7 6 ) , a n d ( 7 7 ) ) s h im p a c k C .

5 . I n s t a l l o u t p u t s p e e d s e n s o r ( 4 5 ) ( F o l d o u t 1 4 ) . 6 . I n s t a ll t w o M 8 x 1 . 2 5 x 2 5 b o lt s ( 4 6 ) a n d t ig h t e n t h e m t o 2 4 – 2 9 N ∙ m ( 1 8 – 2 1 lb f t ) . 7 . I n s t a l l C 7 c o n t r o l v a l v e b o d y a s s e m b l y ( 2 9 ) . 8 . I n s t a l l s ix M 8 x 1 . 2 5 x 5 0 b o l t s ( 4 1 ) , a n d t ig h t e n t h e m t o 2 4 – 2 9 N ∙ m ( 1 8 – 2 1 lb f t ) . 9 . I n s t a l l n e w t r a n s f e r c a s e g a s k e t ( 1 6 ) ( F o l d o u t 1 3 ) . 1 0 . I n s t a l l r e a r t r a n s f e r c a s e c o v e r ( 2 ) ( F o l d o u t 1 4 ) o n t o t h e f r o n t t r a n s f e r c a s e . I f n e c e s s a r y , u s e s o f t f a c e m a l le t t o s e a t t h e c a s e h a lf . 1 1 . I n s ta ll fi ft e e n M 1 0 x 1 . 5 x 1 0 0 b o lt s ( 1 7 ) ( F o l d o u t 1 2 - 2 ) . T i g h t e n t h e b o l t s t o 5 1 – 6 1 N ∙ m ( 3 8 – 4 5 l b f t ) . N O T g e a r th e p in s t a re a r

E : F o l l o w S t e p b e a r in g p r e lo a r o c e d u r e w it h lle d , b u t w it h th o u tp u t h o u s in g

s 1 2 th r o u g h d p ro c e d u re a ll c a s e -to - c e C 6 h o u s in r e m o v e d .

2 7 fo r . P e r fo a s e b o g a n d

d r i v e r m l t s t h e

1 2 . I n s t a l l t e s t fi x t u r e s w h e r e C 6 h o u s in g a n d r e a r o u t p u t h o u s i n g w o u l d n o r m a l l y b e i n s t a l l e d . I n p l a c e o f t h e C 6 h o u s in g , u s e a p l a t e a s t h e t e s t fi x t u r e w it h t h e s a m e h o l e p a t t e r n , s iz e a n d d i a m e t e r a s t h e C 6 h o u s in g . I n p l a c e o f t h e r e a r o u t p u t h o u s i n g , u s e a p l a t e w it h t h e s a m e d i a m e t e r , h o l e p a t t e r n a n d s iz e . W h e n s p e c i a l fi x t u r e p l a t e s a r e n o t a v a i l a b l e , u s e w a s h e r s o r s p a c e r s u n d e r t h e b o l t h e a d s r e t a i n i n g t h e C 6 h o u s in g a n d r e a r o u t p u t h o u s in g .

1 9 . I n s t a l l m a n i f o l d ( 7 3 ) ( F o l d o u t 1 3 ) . 2 0 . I n s ta ll e ig h t M 1 0 x 1 . 5 x 3 5 b o lt s ( 7 1 ) a n d t i g h t e n t o 5 1 – 6 1 N ∙ m ( 3 8 – 4 5 lb f t ) . T w o b o l t s w i l l r e p l a c e g u i d e p i n s . 2 1 . R o t a t e t h e t r a n s f e r c a s e a s s e m b ly s o t h e r e a r s id e is f a c i n g u p . 2 2 . I n s t a l l J – 3 9 6 2 3 B e a r in g E n d P la y C h e c k e r i n t o d r i v e g e a r ( 1 9 ) . 2 3 . I n s t a l l a d i a l i n d i c a t o r , m a k i n g s u r e t h e e n d o f t h e i n d i c a t o r r e s t s s q u a r e l y o n t h e r a i s e d c e n t e r a r e a o f t h e t o o l . 2 4 . B o t t o m t h e a s s e m b l y b y a p p ly in g d o w n w a r d f o r c e a n d r o t a t i n g t o o l J – 3 9 6 2 3 B e a r i n g E n d P la y C h e c k e r . 2 5 . Z e r o t h e d ia l in d i c a t o r w h e n t h e r e is n o m o r e d o w n w a r d m o v e m e n t. 2 6 . U s in g a h o is t a n d a s c a le , a p p ly 7 3 4 – 7 7 8 N ( 1 6 5 – 1 7 5 lb s ) o f u p w a r d f o r c e . 2 7 . R e o r t h e 0 .0

c o r d th re m o v e s p e c ifi 2 5 – 0 .1

e d s h e d 2 7

ia l in d ic a to r im s if t h e r e lim it s ; t h e a m m (0 .0 0 1 –

re a d in a d in g llo w a b 0 .0 0 5

g a is n le e in c

n d a d d o t w i t h i n n d p l a y i s h ) .

N O T E : F o l l o w S t e p s 2 8 t h r o u g h 3 4 f o r d r i v e n g e a r b e a r in g p r e l o a d p r o c e d u r e . 2 8 . I n s t a l l J – 3 9 6 2 3 B e a r in g E n d P la y C h e c k e r in t o d r i v e n g e a r a s s e m b l y ( 8 0 ) ( F o l d o u t 1 3 ) . 2 9 . I n s t a l l a d i a l i n d i c a t o r , m a k i n g s u r e t h e e n d o f t h e i n d i c a t o r r e s t s o n t h e r a i s e d c e n t e r a r e a o f t h e t o o l .

1 3 . R o t a t e t h e a s s e m b ly s o t h e f r o n t s i d e o f t h e t r a n s f e r c a s e i s f f a c i n g u p . C o p y r i g h t ©


5 - - 5 7

S E R V IC E


3 0 . B o t t o m t h e a s s e m b l y b y a p p ly in g d o w n w a r d f o r c e a n d r o t a t in g J – 3 9 6 2 3 B e a r in g E n d P la y C h e c k e r .

4 5 . I n s t a ll fi v e M 1 0 x 1 . 5 x 4 0 b o lt s ( 2 2 ) a n d t ig h t e n t h e m t o 5 1 – 6 1 N ∙ m ( 3 8 – 4 5 lb f t ) . T w o b o l t s r e p la c e t h e g u id e p i n s .

3 1 . Z e r o t h e d ia l in d i c a t o r w h e n t h e r e is n o m o r e d o w n w a r d m o v e m e n t.

4 6 . R e m o v e f r o n t i d l e r c o v e r b o l t s ( 2 2 ) , i d l e r c o v e r ( 2 3 ) , s h i m p a c k B , a n d g a s k e t ( 2 8 ) t o s t a r t t h e id l e r g e a r b e a r i n g p r e l o a d c h e c k .

3 2 . U s in g a h o is t a n d a s c a le , a p p ly 7 3 4 – 7 7 8 N ( 1 6 5 – 1 7 5 lb s ) o f u p w a r d f o r c e . 3 3 . R e o r th e 0 .0

c o r d th re m o v e s p e c ifi 2 5 – 0 .1

e d s h e d 2 7

ia l in d ic a to r im s if t h e r e lim it s ; t h e a m m (0 .0 0 1 –

re a d a d in llo w a 0 .0 0

in g g is b le 5 in

a n n o e n c h

d a d d t w i t h i n d p l a y i s ) .

3 4 . I f t h e p r e l o a d r e a d i n g i s n o t w i t h i n t h e s p e c i fi e d lim i t , a d d o r r e m o v e t h e s h im s , a n d r e c h e c k t h e p r e l o a d . N O T E : F o l l o w S t e p s 3 5 t h r o u g h 5 3 f o r i d l e r g e a r b e a r in g p r e l o a d p r o c e d u r e .

N O T E : B o t h i d l e r c o v e r s m u s t b e i n s t a l l e d a n d t i g h t e n e d t o e s t a b l i s h t h e i d l e r g e a r p o s it io n b e f o r e b e a r in g p r e l o a d is c h e c k e d .

4 7 . I n s t a ll t h e h a n d l e o f J – 3 9 6 2 3 B e a r in g E n d P l a y C h e c k e r i n t o t h e t h r e a d e d h o l e o f i d l e r g e a r ( 3 9 ) . 4 8 . M o u n t t h e d i a l in d ic a t o r . 4 9 . B o t t o m t h e i d l e r g e a r a s s e m b l y b y s li g h t l y r o t a t in g J – 3 9 6 2 3 B e a r in g E n d P la y C h e c k e r w h i le a p p l y in g d o w n w a r d f o r c e . 5 0 . Z e r o t h e d i a l in d ic a t o r . 5 1 . U s e a c h a in h o i s t a n d a p p ly 7 3 4 – 7 7 8 N ( 1 6 5 – 1 7 5 lb s ) o f u p w a r d f o r c e . 5 2 . R e a d d i a l i n d i c a t o r t o d e t e r m i n e b e a r i n g p r e l o a d . 5 3 . If p re lo o r re m 5 3 . T h m m (0

a d is o v e s e a llo .0 0 1 –

n o h im w a 0 .0

t w it h s a n b le e 0 5 in

i n t h e s p e c i fi e d l i m i t s , a d d d r e p e a t S t e p s 4 1 t h r o u g h n d p la y is 0 . 0 2 5 – 0 . 1 2 7 c h ) .

3 5 . I n s t a l l g u i d e p i n s i n t w o r e a r i d l e r c o v e r b o l t h o l e s .

5 4 . W h e n p r e l o a d is w it h i n t h e s p e c i fi e d lim it s , r e m o v e t h e s p e c i a l t o o ls .

3 6 . I n s t a l l n e w g a s k e t ( 4 7 ) ( F o l d o u t 1 4 ) o v e r g u i d e p i n s . I n s t a l l n e w O - r i n g ( 4 8 ) o n i d l e r c o v e r ( 4 9 ) .

5 5 . I n s t a l l g u i d e p i n s t o e a s e i n s t a l l a t i o n o f t h e f r o n t i d l e r c o v e r .

3 7 . L u g u (5 ft)

b e id e 0 ) a . T w

O - r in g a n d p in s . In s ta n d t ig h te n o b o lt s r e p

in ll th la

s ta fi v e e m c e

ll id le M 1 0 to 5 1 th e g

r c x – 6 u id

o v e 1 .5 1 N e p

r ( x ∙m in s

4 9 ) o v e r 4 0 b o l t s ( 3 8 – 4 5 lb .

3 8 . R o t a t e t h e t r a n s f e r c a s e a s s e m b l y s o t h e f r o n t s id e is f a c i n g u p .

5 6 . I n s t a l l a n e w g a s k e t ( 2 8 ) o v e r t h e g u i d e p i n s a n d o n t o t h e t r a n s f e r c a s e . 5 7 . In s ta ll s h im s ( 2 5 ) , ( 2 6 ) , a n d ( 2 7 ) ( s h im B ) .

p a c k

5 8 . L u b e O - r in g ( 2 4 ) . 5 9 . I n s t a l l O - r in g ( 2 4 ) o n i d l e r c o v e r ( 2 3 ) .

3 9 . I n s t a l l g u i d e p i n s t o e a s e i n s t a l l a t i o n o f t h e f r o n t i d l e r c o v e r .

6 0 . I n s t a l l i d l e r c o v e r ( 2 3 ) , a n d t a p i t l i g h t l y f o r i n s t a l l a t i o n .

4 0 . I n s t a l l a n e w g a s k e t ( 2 8 ) ( F o l d o u t 1 3 ) o v e r t h e g u i d e p i n s a n d o n t o t h e t r a n s f e r c a s e .

6 1 . I n s t a ll fi v e M 1 0 x 1 . 5 x 4 0 b o lt s ( 2 2 ) a n d t ig h t e n t h e m t o 5 1 – 6 1 N ∙ m ( 3 8 – 4 5 lb f t ) . T w o b o l t s r e p la c e t h e g u id e p i n s .

4 1 . In s ta ll s h im s ( 2 5 ) , ( 2 6 ) , a n d ( 2 7 ) ( s h im B ) o v e r t h e g u i d e p in s . 4 2 . L u b e a n e w 4 3 .

p a c k

6 2 . I n s t a ll a n e w O - r in g o n t o t h e m a in w ir in g h a r n e s s c o n n e c t o r ( 3 1 ) .

O - r in g ( 2 4 ) .

I n s t a l l O - r in g ( 2 4 ) o n id l e r c o v e r ( 2 3 ) .

4 4 . I n s t a l l i d l e r c o v e r ( 2 3 ) a n d t a p i t l i g h t l y w i t h a s o f t - f a c e d m a l l e t t o s e a t i t i n p o s i t i o n .

5 - 5 8

C o p y r ig h t ©

6 3 . I n s t a l l e l e c t r i c a l c o n n e c t o r a s s e m b l y ( 3 1 ) o n t o t h e c o n n e c t o r p l a t e ( 2 9 ) a n d t ig h t e n n u t ( 8 8 ) t o 2 . 7 3 – 4 . 0 9 N ∙ m ( 2 4 – 3 6 lb in c h ) . 6 4 . P la c e a n e w g a s k e t ( 3 0 ) o n t h e c o n n e c t o r p l a t e , c a r e f u l l y r o t a t i n g w i r i n g h a r n e s s t h r o u g h t h e g a s k e t .


M O D U L E 6 5 . P o s i t i o n t h e w i r i n g h a r n e s s c o n n e c t o r t h r o u g h t h e t r a n s f e r c a s e a n d t h e c o n n e c t o r p l a t e . 6 6 . I n s ta ll f o u r M 8 x 1 . 2 5 x 2 5 b o lt s ( 3 2 ) a n d t ig h t e n t h e m t o 5 – 8 N ∙ m ( 4 – 6 lb f t ) . 6 7 . L u b e a n d I n s t a ll a n e w O - r in g ( 5 ) o n s u c t io n h o s e fi t t in g ( 2 ) . ( F ig u r e 5 – 7 1 ) .

R E B U IL D 7 5 . I n s t a l l fi f t e e n b o l t s M 1 0 x 1 . 5 x 4 0 ( 4 5 ) a n d t i g h t e n t h e m t o 5 1 – 6 1 N ∙ m ( 3 8 – 4 5 lb f t ) . T w o b o l t s w i l l r e p l a c e g u i d e p i n s . 7 6 . R o t a t e t h e a s s e m b l y s o t h e r e a r s id e is f a c in g u p . 7 7 . R e c (3 1 ) s o le lo c k

o n n e to s n o id s in

c t p e (3 p la

m a i n e l e c t r ic a l c o n n e c t o r a s s e m b l y e d s e n s o r ( 4 5 ) ( F o ld o u t 1 4 ) a n d 5 ) , m a k in g s u r e e a c h c o n n e c t o r c e .

7 8 . In s ta ll a n e w

c o n t r o l v a l v e c o v e r g a s k e t ( 4 2 ) .

7 9 . I n s t a l l c o n t r o l v a l v e c o v e r ( 4 3 ) . 8 0 . I n s ta ll t e n M 8 x 1 . 2 5 x 3 0 b o lt s ( 4 4 ) , a n d t ig h t e n t h e m t o 2 4 – 2 9 N ∙ m ( 1 8 – 2 1 lb f t ) . 8 1 . I f n o t p r e v i o u s l y d o n e , r e m o v e t h e t e s t fi x t u r e s i n s t a l l e d d u r i n g d r i v e a n d d r i v e n g e a r b e a r i n g p r e l o a d . 8 2 . P o s i t io n P 4 c a r r ie r a s s e m b l y ( 5 6 ) o n t h e t r a n s f e r c a s e . 8 3 . I n s t a l l t w o g u i d e b o l t s t o f a c i l i t a t e i n s t a l l a t i o n o f r e a r o u t p u t h o u s i n g ( 7 4 ) . 8 4 . In s ta ll a n e w

g a s k e t ( 7 3 ) .

8 5 . C a r e f u l l y i n s t a l l r e a r o u t p u t h o u s i n g a s s e m b l y ( 7 4 ) o n t o t h e t r a n s f e r c a s e . 8 6 . In s ta ll M 1 0 x 5 1 – 6 1 g u id e

s ix M 1 .5 N ∙m b o lt s

1 0 x 1 . 5 x 4 0 b o l t s ( 7 5 ) a n d n i n e x 1 0 0 b o lt s ( 8 2 ) . T ig h te n t h e m t o ( 3 8 – 4 5 l b f t ) . T w o b o l t s w i l l r e p l a c e .

8 7 . I n s t a l l g u i d e b o lt s i n t w o C 6 c o v e r b o l t h o le s . F ig u r e 5 – 7 1 . T r a n s fe r C a s e F ittin g S c r e e n I n s t a l l a t i o n

A n d

6 8 . L u b e t h e m e t a l b o s s o f t h e fi lt e r s c r e e n ( 6 ) a n d p o s i t i o n i t i n t h e fi t t i n g ( 2 ) . 6 9 . C a r e f u l l y t h r e a d t h e fi t t i n g i n t o t h e t r a n s f e r c a s e . 7 0 . T i g h t e n t h e ja m n u t o n fi t t in g ( 2 ) t o 1 0 0 – 1 2 0 N ∙ m ( 7 4 – 8 9 lb f t ) . 7 1 . I n s t a l l C 7 c l u t c h a s s e m b l y ( 5 8 ) ( F o l d o u t 1 3 ) i n t o t h e t r a n s f e r c a s e .

8 8 . In s ta ll a n e w

g a s k e t ( 2 2 ) .

8 9 . P o s it io n C 6 c lu t c h h o u s in g a s s e m b l y ( 5 ) o n t h e t r a n s f e r c a s e . 9 0 . I n s t a l l fi f t e e n b o l t s ( 2 3 ) a n d t w o b o l t s ( 2 4 ) . T ig h t e n t h e m t o 5 1 – 6 1 N ∙ m ( 3 8 – 4 5 lb f t ) . T w o b o l t s w i l l r e p l a c e g u i d e b o l t s . 9 1 . P e in s tra o f

r fo r m s ta l lin g n s m is s T ra n s fe

e le th e io n r C

c tiv e tra n a s e a s e

s h im s fe r c x p la in M o d u

m e a s e e d le (

a s in in F ig

u re m to th 6 – 2 n u re

e n t b e f o r e e m a i n . I n s t a l l a t i o n 6 – 1 3 ) .

7 2 . I n s t a l l g u i d e p i n s i n t w o f r o n t o u t p u t h o u s i n g b o l t h o l e s . 7 3 . In s ta ll a n e w

o u t p u t h o u s in g g a s k e t ( 5 0 ) .

7 4 . P o s i t i o n f r o n t o u t p u t h o u s i n g ( 4 9 ) o n t h e t r a n s f e r c a s e .

C o p y r ig h t ©

2 0 0 9


5 - 5 9


S E R V IC E

5 – 1 7 .

C O N T R O L V A L V E M O D U L E ( F o l d o u t 1 5 - 1 , F o l d o u t 1 5 - 2 ) C A U T IO N : • T p d a c

o h e lp ro te c t u r in g n d in s o n t a in

p re v e n t tra n c o n tro l v a lv r e m o v a l, c le t a lla t io n . K e e r s u n t il t h e

s m is e m o a n in g e p th y a re

s io n d a m a g e , d u l e p a r t s , i n s p e c t i o n , e m i n c l e a n i n s t a l l e d .

• C s m p r J S r

o n t r o l v a lv e m o d u le a s s e m b ly p r i n g s a n d o t h e r p a r t s c a n b e i s t a k e n l y in t e r c h a n g e d . T a g e a c h a r t w it h it s it e m n u m b e r a s i t is e m o v e d a n d u s e V a lv e T r a y S e t – 3 3 1 6 3 V a lv e B o d y P a r t s T r a y e t t o s i m p l i f y c o r r e c t v a l v e b o d y e a s s e m b l y .

• C o n t r o l v a lv e m o d u le p a r t s fi t t o g e t h e r c lo s e l y a n d h a v e s p e c i fi c o p e r a t in g c le a r a n c e s . T h e y c a n b i n d if d a m a g e d . T h e s e p a r t s d e p e n d u p o n s m o o t h s e a lin g s u r f a c e s a n d m a y l e a k i f t h e s e a l i n g s u r f a c e i s s c r a t c h e d . V a lv e s , w h e n d r y , m u s t m o v e f r e e ly b y t h e ir o w n w e ig h t in t h e i r b o r e s . C a r e f u l l y h a n d l e a l l s u c h p a r t s .

N s c g e o C o a .

O T E : R e f e r t o S I L 1 e r v ic e in f o r m a t io n r e o n t a m in a tio n fr o m w ly c o l. T h e p r e s e n c e t h y le n e g l y c o l c o o l a n il is d e t r im e n t a l t o t h e o n t a m in a te d o i l h a s n t r a n s m i s s io n c o m p

8 -T R -9 8 fo g a r d in g s u a te r o r e th o f w a te r a t in th e t r a in te r n a l c o a d e t e r io r a o n e n t s .

b . R e m o v a l o f E l e c t r i c a l C o m p o n e n t s a n d S e n s o r s . N T C a c c p s

O T E : R e f e r t o T r o u S 3 9 8 9 E N ( A llis o n 4 o n tro ls ) fo r th e c o m n d re p a ir p r o c e d u re o m p o n e n t s u s e d in o n tr o ls , s u c h a s fo r in s w ir e h a r n e s s e s , w i t c h e s , e t c .

N O T E : B S /N 6 5 1 0 a ll s p e e d T a b le 3 – 2 fo rm e r s e A .

e g in 6 3 0 s e n fo r n s o

r d e t a i l e d s p e c t e d y l e n e n d / o r n s m i s s i o n m p o n e n t s . t i n g e f f e c t

R e m o v a l o f F i l t e r s . 1 . If n o c o v e g a s k (1 6 1

t p re v rs (1 5 e ts (1 ), a n d

2 . R e m R e m D is c d a m

o v e o v e a rd a g e

5 - 6 0

io u s ly 8 ) (F o 5 9 ), tw tw o fi

re ld o lt e

m o v e o u t 1 5 O - r in rs (1 6

d , r e m o v e t w o fi lt e r - 1 , F o l d o u t 1 5 - 2 ) , t w o g s ( 1 6 0 ) , t w o O - r i n g s 2 ) .

t h r e e b o lt s ( 3 ) a n d f a c e s e a l ( 6 ) . s u c t io n fi lt e r ( 5 ) a n d g a s k e t ( 7 ) . s u c t i o n fi l t e r ( 5 ) a n d g a s k e t ( 7 ) i f d .

C o p y r i g h t ©


n in g 0 8 9 s o rs s p e rs . R

b le s h o o t in th G e n e r a p l e t e in s p s o f a ll e le th e tra n s m th e c o n n e s e n s o rs , s

J a n a n d w e r c ifi c a e fe r

g M a n u a l t io n e c t i o n c t r i c a l i s s io n c t o r s , o l e n o i d s ,

u a ry 2 0 0 6 S /N 6 5 2 0 0 e r e d e s ig n t io n s o f c u to S IL 5 -W

a n d 5 7 8 e d . rre n T -0

w it h 2 0 , S e e t a n d 6 R e v

M O D U L E

F ig u r e

5 – 7 2 . C o n n e c t o r R e m o v a l

1 . R e m o v e t w o b o lt s ( 9 3 ) a n d t u r b in e s p e e d s e n s o r ( 9 4 ) . M e a s u r e t u r b in e s p e e d s e n s o r r e s i s t a n c e . 2 . If p r L e v th e In s p T S 3

e s e n e l S e O L S e c t in 9 8 9 E

t, re m o v e n s o r (O L S w ith a s o g E le c t r ic N fo r s e n

tw o ) a s ft c lo a l C o s o r o

3 . R c R b s

e m o o n n e e le a y p u c re w

4 . R a o m o b c

e m o v e tw e lv e b o lts s s e m b ly b r a c k e t ( 5 6 f p r e s s u r e s w itc h a s u s t n o t e x c e e d 4 O h f p r e s s u r e s w it c h a s e a t le a s t 2 0 ,0 0 0 O h lo s e b e t w e e n 1 5 9 – 2

b o lts s e m th . R m p o p e ra

(1 3 6 b ly ( 1 e fe r n e n ts t io n .

v e th r e e b o lts ( 4 6 ) fr o m c to r . D is c o n n e c t a ll c o s e c o n n e c t o r s i n t h e w s h in g i n t h e c e n t e r t a b d r iv e r a s s h o w n in F i g u (5 7 ). M s e m m s s e m m s 5 5

) a 3 7 to a

n d ). 3 – n d

fe e d th n n e c to r ir e h a r n w ith a s re 5 – 7 2

) a n d p re a x im u m b ly ( 5 4 ) . M in im u b ly ( 5 4 ) . T h e s w k P a (2 3 –

5 . R e m o v e s o le n o i d ( 7 2 ) a n d O - r i n g s ( 7 3 ) a n d ( 7 4 ) . R e m o v e v a lv e s ( 7 5 ) a n d s p r in g ( 7 6 ) .

O il C l e a n 5 r . / o r

r o u g h s . e s s m a ll .

s s u re r e s is ( c lo s m re s (o p e n it c h s 3 7 p s

s w it c h t a n c e e d ) is t a n c e ) m u s t h o u ld i) .

1 . R e m o v e t w o b o lt s ( 4 8 ) . 2 . R e m o v e b r a c k e t ( 4 7 ) . ift c o n la te (9 a re fu l 5 3 ) a n o n tro l

t r o l v a lv 6 ) fro m n o t t o lo d a c c u m v a lv e b o

e b o d y c o n tro l s e th e u la to r s d y (1 1 8

(1 1 8 ) a n d s v a lv e b o d y f o u r s p r in g s (5 1 ) a n d (5 ) o n a fl a t w

6 . R e m o v e s o le n o i d ( 6 7 ) a n d O - r i n g s ( 6 8 ) a n d ( 6 9 ) . R e m o v e v a lv e ( 7 0 ) a n d s p r in g ( 7 1 ) . 7 . R e m o v e s o le n o i d ( 6 2 ) , O - r in g s ( 6 3 ) a n d ( 6 4 ) , v a l v e ( 6 5 ) a n d s p r in g ( 6 6 ) . 8 . In in re (7

s e r t J – 4 7 9 4 2 V a l v e S p r in g C o m p r e s s o r t o s l o t t o p u s h i n d i a g n o s t i c v a l v e ( 7 8 ) a n d l e a s e c l i p ( 7 7 ) , r e m o v e s p r i n g ( 7 9 ) a n d v a l v e 8 ) .

9 . R e m o v e s o l e n o i d ( 8 0 ) , t w o O - r i n g s ( 8 1 ) a n d ( 8 2 ) , v a l v e ( 8 3 ) a n d s p r in g ( 8 4 ) .

c . D i s a s s e m b l y o f t h e C o n t r o l V a l v e B o d y ( F o l d o u t 1 5 - 1 , F o l d o u t 1 5 - 2 ) .

3 . L p c ( c

R E B U IL D

e p a r a t o r ( 1 1 8 ) b e i n g ( 5 0 ) a n d 2 ) . S e t t h e o r k s u r f a c e .

1 0 . R e m o v e s o le n o i d ( 8 5 ) , t w o O - r in g s ( 8 6 ) a n d ( 8 7 ) , v a l v e ( 8 8 ) a n d s p r in g ( 8 9 ) . 1 1 . R e m o v e s o le n o i d ( 9 0 ) a n d t w o O - r i n g s ( 9 1 ) a n d ( 9 2 ) . d . D i s a s s e m b l y o f F i l t e r L i f e V a l v e B o d y ( F i g u r e 5 – 7 3 ) . N m B S M tr

O T E : F i l t e r L i f e o d e ls e q u i p p e d e g i n n i n g J u ly 2 /N 6 5 1 0 8 2 2 0 0 5 Y 0 9 p r o g n o s t ic a n s m is s io n s . R

V a lv e w ith 0 0 8 a , a n d s w a s e fe r to

B o d y is o n ly P r o g n o s t ic s . n d w it h S /N 6 5 2 0 0 9 9 9 a d d e d to 3 0 0 0 S IL 1 1 -W T -0 8

o n

5 7 , f a m ily .

N O T E : S p e c i a l T o o l s R e q u i r e d : J 4 7 9 4 2 V a lv e S p r in g C o m p r e s s o r

4 . R e m o v e t h r e e f a c e s e a ls ( 4 9 ) . C o p y r ig h t ©

2 0 0 9


5 - 6 1

S E R V IC E

M A N U A L — 3 0 0 0 P r o d u c t F a m i l y — A l l i s o n 4 t h G e n e r a t i o n C o n t r o ls — V O C A T IO N A L M O D E L S is f o u n d . R e p a i r o r r e p l a c e t h e c o n n e c t o r a s r e q u i r e d . S e e 3 – 5 r . I n s p e c t in g E l e c t r ic a l C o m p o n e n t s . e . D i s a s s e m b l y o f C 6 C o n t r o l V a lv e B o d y ( F o l d o u t 1 5 - 1 , F o l d o u t 1 5 - 2 ) . 1 . R e m o v e f o u r b o l t s ( 1 8 5 ) a n d r e m o v e C 6 v a l v e b o d y b r a c k e t ( 1 6 8 ) , s p r i n g ( 1 7 8 ) , a c c u m u l a t o r v a lv e ( 1 7 2 ) a n d v a lv e b o d y ( 1 7 5 ) . 2 . R n O s

e m u t ( - r in p r in

o v e p 1 6 7 ) , g s (1 g (1 7

in ( 1 7 6 ) f o r s o le n o id ( 1 7 5 ) . R e m o v e p l a t e ( 1 6 8 ) , s o l e n o i d ( 1 6 9 ) , t w o 7 0 ) a n d ( 1 7 1 ) , v a l v e ( 1 7 2 ) , a n d 3 ) .

3 . R e m o v e s c r e w ( 1 8 5 ) a n d b r a c k e t ( 1 8 6 ) . R e m o v e s o le n o i d ( 1 8 0 ) , O - r in g s ( 1 8 1 ) a n d ( 1 8 1 ) , v a lv e ( 1 7 9 ) a n d s p r in g ( 1 7 8 ) . 4 . I n s p e c t b o t h v a lv e s a n d b o r e s f o r n i c k s , w e a r , a n d d a m a g e . f . D i s a s s e m b l y o f C o n t r o l V a l v e B o d y ( F o l d o u t 1 5 - 1 , F o l d o u t 1 5 - 2 ) .

F i g u r e 5 – 7 3 . F i l t e r L i f e V a l v e B o d y A s s e m b l y — D is a s s e m b le d V i e w 1 . D i s c o n n e c t i n t e r n a l w i r i n g h a r n e s s c o n n e c t o r ( 1 ) f r o m t h e fi l t e r l if e v a l v e b o d y a s s e m b l y . 2 . R e m o v e f o u r M 6 x 1 . 0 x 4 5 b o lt s ( 2 ) r e t a in in g v a l v e b o d y ( 4 ) a n d p r e s s u r e s w it c h ( 3 ) t o t h e c h a n n e l p l a t e . 3 . R e m o v e v a lv e b o d y ( 4 ) .

1 . R e m o v e t w o b o lt s ( 9 5 ) a n d c o n tr o l v a lv e b o d y a s s e m b l y ( 1 1 8 ) . 2 . L if t c o n t r o l v a lv e b o d y ( 1 1 8 ) a n d s e t o n fl a t w o r k s p a c e . 3 . R e m o v e s o le n o id r e t e n t i o n p i n ( 1 1 4 ) f r o m b o t t o m o f c o n t r o l v a l v e b o d y a s s e m b l y ( 1 1 8 ) . 4 . R e m o v e s o le n o i d ( 1 1 5 ) w it h O - r i n g s ( 1 1 6 ) a n d ( 1 1 7 ) . M e a s u r e t h e r e s i s t a n c e o f t h e s o l e n o i d b y u s in g t h e c h a r t i n F ig u r e 3 – 8 . 5 . R e m o v e v a lv e r e t e n t io n p i n ( 9 8 ) .

4 . R e m o v e p r e s s u r e s w it c h ( 3 ) . 5 . P l a c e fi l t e r l i f e v a l v e b o d y a s s e m b l y ( 4 ) o n t h e w o r k s u r f a c e w it h t h e m a c h i n e d - s id e u p . 6 . U s in g J 4 7 9 4 2 V a lv e S p r in g C o m p r e s s o r , c o m p r e s s v a lv e s p r in g ( 6 ) e n o u g h t o r e m o v e v a l v e r e t a i n i n g c l i p ( 8 ) .

6 . R e m o v e s to p ( 1 0 1 ) , s p r in g ( 1 0 0 ) , a n d lo c k u p r e l a y v a l v e ( 9 9 ) . 7 . R e m o v e v a lv e r e t e n t io n p i n ( 1 0 2 ) . 8 . R e m o v e s t o p ( 1 0 5 ) , s p r i n g ( 1 0 4 ) , a n d lu b e r e g u l a t o r v a l v e ( 1 0 3 ) .

7 . R e m o v e v a l v e r e t a i n i n g c lip ( 8 ) . 8 . R e m o v e v a lv e s t o p ( 7 ) , s p r in g ( 6 ) , a n d v a lv e ( 5 ) . 9 . I n s p e c t a ll p a r t s f o r w e a r , d a m a g e , o r b u r r s . R e p la c e p a r t s t h a t a r e w o r n o r d a m a g e d . 1 0 . M e s w o r (1 ) p re 5 - 6 2

a s u re it c h ( 3 w e a r. fo r d a s s u re

r e s is ta n c ) a n d its In s p e c t p m a g e o r s w itc h if

e a n w ir in re s s lo o s e x c e

d in s p g le a d u re s w e p in s s s iv e

e c t p re s s u s fo r d a m a itc h c o n n e . R e p la c e w e a r o r d a

C o p y r ig h t ©

r e g e c t o r t h e m a g e

W h d o

A R N ig h ly u r in g c c u r

9 . In s ta R e m s p r in a n d

IN G c o m d is a if t h e

ll J – o v e g (1 c a re

: S p re s s e s p

p r in s s e m b r in g

3 5 9 2 4 M r / In s t a lle r 0 8 ) , r e m o f u lly r e m o


g s d . ly . fo

(1 0 B e P e rc e

a in P ( F ig u v e v a v e J

8 ) a n e x tre rs o n a is n o

d ( 1 1 2 ) a r e m e l y c a r e f u l l i n j u r y c a n t c o n t r o l l e d .

re s s u re re 5 – 7 4 l v e r e t e 3 5 9 2 4 M

S p r in g ) . C o m p r e s s n t i o n p i n n ( 1 0 6 ) , a i n P r e s s u r e

M O D U L E S p r i n g R e m o v e r / I n s t a l l e r a f t e r t u r n i n g h a n d l e c o u n t e r c l o c k w i s e t o r e l e a s e s p r i n g f o r c e .

R E B U IL D 2 . R e m o v e d r a in p lu g ( 1 5 5 ) a n d O - r in g ( 1 5 4 ) o r d r a i n p l u g ( 1 4 9 ) a n d O - r in g ( 1 4 8 ) . 3 . R e m o v e e ig h t p r e s s u r e t a p p lu g a s s e m b lie s ( 1 5 6 ) w i t h O - r i n g s ( 1 5 7 ) o r n i n e p l u g s ( 1 4 5 ) w i t h O - r i n g s ( 1 4 6 ) . 4 . R e m o v e O - r in g s fr o m

a ll p lu g s .

h . A s s e m b l y o f t h e C h a n n e l P l a t e ( F o l d o u t 1 5 - 1 , F o l d o u t 1 5 - 2 ) . 1 . In s ta ll n e w

O - r in g s o n a l l p l u g s .

2 . I n s t a l l e i g h t p r e s s u r e t a p p l u g s ( 1 5 6 ) o r n i n e p lu g s ( 1 4 5 ) . T i g h t e n p lu g s t o 1 0 – 1 3 N ∙ m ( 7 – 1 0 l b f t ) . 3 . I n s t a l l d r a i n p l u g ( 1 5 3 ) o r ( 1 4 7 ) . T i g h t e n p l u g t o 2 5 – 3 2 N ∙ m ( 1 8 – 2 4 lb f t ) . 4 . I f r e m o v e d , in s t a l l t w o d o w e l p i n s ( 1 5 1 ) o r ( 1 4 3 ) . 5 . I n s t a l l g a s k e t ( 1 6 5 ) , s e p a r a t o r p l a t e ( 1 3 9 ) , a n d c h a n n e l g a s k e t ( 1 4 0 ) .

F i g u r e 5 – 7 4 . U s e o f T o o l t o R e le a s e M a i n - P r e s s u r e V a l v e S p r i n g F o r c e

i. A s s e m b ly o f t h e M a in V a lv e B o d y ( F o l d o u t 1 5 - 1 , F o l d o u t 1 5 - 2 ) .

1 0 . R e m o v e s to p ( 1 0 9 ) , s p r in g ( 1 0 8 ) , a n d m a in r e g u l a t o r v a l v e ( 1 0 7 ) . 1 1 . R e m o v e v a lv e r e t e n t io n p i n ( 1 1 0 ) .

1 . I n s t a l l c o n v e r t e r r e g u l a t o r v a l v e ( 1 3 3 ) , s p r i n g ( 1 3 4 ) , a n d s t o p ( 1 3 5 ) .

1 2 . R e m o v e c lip ( 1 1 3 ) , s p r in g ( 1 1 2 ) , a n d c o n t r o l m a i n v a l v e ( 1 1 1 ) .

2 . I n s t a l l v a l v e r e t e n t i o n p i n ( 1 3 2 ) .

1 3 . R e m o v e v a lv e r e t e n t io n p i n ( 1 2 1 ) .

3 . I n s t a l l C 1 l a t c h v a l v e ( 1 2 9 ) , s p r i n g ( 1 3 0 ) , a n d s t o p ( 1 3 1 ) .

1 4 . R e m o v e s to p ( 1 2 4 ) , s p r in g ( 1 2 3 ) , a n d C 2 la t c h v a lv e ( 1 2 2 ) .

4 . I n s t a l l v a l v e r e t e n t i o n p i n n ( 1 2 0 ) .


5 . I n s t a l l e x h a u s t b a c k v a l v e ( 1 2 6 ) , s p r in g ( 1 2 7 ) , a n d s to p ( 1 2 8 ) .

1 6 . R e m o v e s to p ( 1 2 8 ) , s p r in g ( 1 2 7 ) , a n d e x h a u s t b a c k v a lv e ( 1 2 6 ) .



7 . I n s t a l l C 2 l a t c h v a l v e ( 1 2 2 ) , s p r i n g ( 1 2 3 ) , a n d s t o p ( 1 2 4 ) .

1 8 . R e m o v e s to p ( 1 3 1 ) , s p r in g ( 1 3 0 ) , a n d C 1 l a t c h i n g v a l v e ( 1 2 9 ) .



9 . I n s t a l l c o n t r o l m a i n v a l v e ( 1 1 1 ) , s p r i n g ( 1 1 2 ) , a n d c l ip ( 1 1 3 ) .

2 0 . R e c o 1 3 R e a n

m o v e s n v e rte r 5 fo r b a m o v e g d c h a n n

to p ( 1 re g u la t te r in g a s k e t e l p la

3 5 ) to r a n (1 6 te g

, s p rin g v a lv e 1 3 d r e p la c 5 ), s e p a a s k e t (1

( 1 3 4 ) , a n d 3 . I n s p e c t s t o p e i f it is b a t t e r e d . r a t o r p l a t e ( 1 3 9 ) , 4 0 ) .

1 0 . I n s t a l l v a l v e r e t e n t i o n p i n ( 1 1 0 ) . 1 1 . I n s t a l l m a i n r e g u l a t o r v a l v e ( 1 0 7 ) , s p r i n g ( 1 0 8 ) , a n d s t o p ( 1 0 9 ) .

g . D i s a s s e m b l y o f t h e C h a n n e l P l a t e ( F o l d o u t 1 5 - 1 , F o l d o u t 1 5 - 2 ) . 1 . I f d a m a g e d , r e m o v e t h e t w o d o w e l p in s ( 1 5 1 ) o r ( 1 4 3 ) . C o p y r ig h t ©

2 0 0 9

1 2 . In s ta ll J – 3 5 R e m o v e r/In s p r in g ( 1 0 8 (1 0 6 ), a n d S p r in g R e m

9 2 4 M a in P r e s t a lle r ( F ig u r e ) , in s t a ll v a lv e re m o v e J – 3 5 9 o v e r /I n s t a l le r


s s u r e S p r in g 5 – 7 4 ) . C o m p r e s s r e t e n t i o n p i n 2 4 M a in P r e s s u r e a f t e r t u r n i n g h a n d l e

5 - 6 3

S E R V IC E


c o u n t e r c l o c k w i s e u n t i l t h e t o o l c l e a r s p i n ( 1 0 6 ) . 1 3 . I n s t a l l l u b e r e g u l a t o r v a l v e ( 1 0 3 ) , s p r i n g ( 1 0 4 ) , a n d s t o p ( 1 0 5 ) . 1 4 . I n s t a l l v a l v e r e t e n t i o n p i n ( 1 0 2 ) . 1 5 . I n s t a l l l o c k u p r e l a y v a l v e ( 9 9 ) , s p r i n g ( 1 0 0 ) , a n d s t o p ( 1 0 1 ) . 1 6 . I n s t a l l v a l v e r e t e n t i o n p i n ( 9 8 ) . 1 7 . I n s t a l l O - r i n g s ( 1 1 6 ) a n d ( 1 1 7 ) o n s o l e n o i d ( 1 1 5 ) a n d i n s t a l l s o l e n o i d . 1 8 . I n s t a l l s o l e n o i d r e t e n t i o n p i n ( 1 1 4 ) t h r o u g h b o t t o m o f c o n t r o l v a l v e b o d y a s s e m b l y ( 1 1 8 ) . 1 9 . I n s t a l l s o l e n o i d s e p a r a t o r p l a t e ( 9 6 ) o n t o p o f c o n t r o l v a l v e b o d y a s s e m b l y ( 1 1 8 ) .

l l s p r i n n g ) a n d (1 7 1 6 7 ) a n d a lv e b o d

2 . In s ta ll s p (1 8 2 ) a n (1 8 6 ). S s c re w (1

(1 7 5 1 ), C s o le y (1 7

) , v a l v v e ( 1 7 4 ) , t w o O - r i n g s 6 e n a b le s o le n o i d ( 1 6 9 ) , n o i d r e t e n t i o n p i n ( 1 7 6 ) i n t o 5 ) .

r i n g ( 1 7 8 ) , v a l v e ( 1 8 0 ) , t w o O - r i n g s d ( 1 8 1 ) , s o l e n o i d ( 1 8 0 ) , a n d b r a c k e t e c u r e t o C 6 v a lv e b o d y ( 1 7 5 ) w it h 8 5 ) .

3 . In s ta l l s p r in v a lv e b o d y fo u r b o lts ( N ∙m (7 – 1 0

6 . I n s t a l l f o u r M 6 x 1 . 0 x 4 5 b o l t s ( 2 ) r e t a i n i n g t h e p r e s s u r e s w i t c h a n d v a l v e b o d y . T i g h t e n f o u r b o l t s fi n g e r - t i g h t . 7 . T ig h t e n f o u r M 6 x 1 . 0 x 4 5 b o lt s ( 2 ) t o 1 0 – 1 3 N ∙ m ( 7 – 1 0 lb f t ) . 8 . C o n n e c t t h e in t e r n a l w i r in g t o t h e p r e s s u r e s w i t c h c o n n e c t o r . l. A s s e m b ly o f t h e S o l e n o id V a lv e B o d y ( F o l d o u t 1 5 - 1 , F o l d o u t 1 5 - 2 ) . 1 . I n s t a l l s o l e n o i d ( 9 0 ) , t w o O - r in g s ( 9 1 ) a n d ( 9 2 ) . 2 . I n s t a l l s p r i n g ( 8 9 ) , v a l v e ( 8 8 ) , O - r i n g s ( 8 6 ) a n d ( 8 7 ) a n d s o l e n o id ( 8 5 ) . 3 . I n s t a l l s p r i n g ( 8 4 ) , v a l v e ( 8 3 ) , t w o O - r i n g s ( 8 1 ) a n d ( 8 2 ) , a n d s o l e n o i d ( 8 0 ) .

j . A s s e m b l y o f C 6 C o n t r o l V a l v e B o d y ( F o l d o u t 1 5 - 1 , F o l d o u t 1 5 - 2 ) . 1 . In s ta (1 7 0 n u t ( C 6 v

b o d y s o t h a t t h e p r e s s u r e s w i t c h a s s e m b l y b o l t h o l e s a l ig n w i t h t h r e e v a l v e b o d y b o l t h o l e s .

g ( 1 7 7 ) a n d a c c u m u l a t o r ( 1 7 9 ) i n t o ( 1 7 5 ) . I n s t a l l b r a c k e t ( 1 6 8 ) a n d 1 6 7 ) . T i g h t e n t h e b o l t s t o 1 0 – 1 3 lb f t ) .

k . A s s e m b l y o f F i l t e r L i f e V a lv e B o d y ( F i g u r e 5 – 7 3 ) . 1 . W i t h fi l t e r l i i f e v a l v e b o d y m a c h i n e d s i d e u p o n t h e w o r k s u r f a c e , i n s t a l l v a l v e ( 5 ) , s p r i n g ( 6 ) , a n d v a lv e s t o p ( 7 ) . 2 . U s in g J 4 7 9 4 2 V a lv e S p r in g C o m p r e s s o r , c o m p r e s s s p r in g ( 6 ) f a r e n o u g h t o in s t a l l r e t a i n i n g c l i p ( 8 ) . 3 . I n s t a l l r e t a i n i n g c l i p ( 8 ) s o t h a t t h e c l i p i s b e l o w t h e m a c h i n e d s u r f a c e . 4 . P o s it io n v a lv e b o d y a s s e m b l y ( 4 ) o n c h a n n e l p l a t e a s s e m b l y s o t h a t f o u r b o l t h o l e s a l i g n w it h t h e ir t h r e a d e d h o l e s in t h e c h a n n e l p la t e . 5 . I n s t a l l p r e s s u r e s w i t c h ( 3 ) a s s e m b l y , w i r e le a d s u p , o n t o t h e m a c h in e d a r e a o f t h e v a lv e

4 . I n s t a l l v a l v e ( 7 8 ) , a n d s p r i n g ( 7 9 ) . I n s e r t J – 4 7 9 4 2 V a lv e S p r in g C o m p r e s s o r i n t o s lo t t o p u s h i n v a l v e a n d i n s t a l l c l i p ( 7 7 ) . 5 . I n s t a l l s p r i n g ( 6 6 ) , v a l v e ( 6 5 ) , a n d s o l e n o i d ( 6 2 ) w it h t w o O - r in g s ( 6 3 ) a n d ( 6 4 ) . 6 . I n s t a l l s p r i n g ( 7 1 ) , v a l v e ( 7 0 ) , a n d s o l e n o i d ( 6 7 ) w it h t w o O - r in g s ( 6 8 ) a n d ( 6 9 ) . 7 . I n s t a l l s p r i n g ( 7 6 ) , v a l v e ( 7 5 ) , a n d s o l e n o i d ( 7 2 ) w i t h O - r in g s ( 7 3 ) a n d ( 7 4 ) . 8 . I n s t a l l t h r e e f a c e s e a l s ( 4 9 ) . 9 . I n s t a l l a c c u m u l a t o r p l u g s ( 5 1 ) a n d ( 5 2 ) a n d s p r in g s ( 5 4 ) a n d ( 5 7 ) . 1 0 . I n s t a l l s e p a r a t o r p l a t e ( 9 6 ) o n b o t t o m s o f s o le n o id v a lv e b o d y a n d p l a c e t h e s o le n o id v a lv e b o d y o n t o p o f m a i n v a lv e b o d y ( 1 1 8 ) . 1 1 . I n s t a l l b r a c k e t ( 4 7 ) . 1 2 . I n s t a l l b r a c k e t ( 5 6 ) w i t h d i a g n o s t i c p r e s s u r e s w i t c h ( 5 5 ) . 1 3 . I n s t a l l t w e l v e b o l t s ( 5 7 ) . I n s t a l l t w o b o l t s ( 4 8 ) . m . I n s t a l l a t i o n o f E l e c t r i c a l C o m p o n e n t s a n d S e n s o r s ( F o l d o u t 1 5 - 1 , F o l d o u t 1 5 - 2 ) . 1 . In s ta c o n n S e c u b o lts b o lts

ll 2 4 - w e c to r ( re c o n (5 0 ). 5 0 to

a y 1 3 n e C o 1 .3

in t e r n a l c ) w it h w ir e c to r a s s e n n e c t a ll – 2 .7 N ∙m

o n n e h a rn m b ly c o n n (1 2 –

2 . R e c o n n e c t a ll c o n n e c t o r s . 5 - 6 4

C o p y r ig h t ©


c to r fe e d e s s a s s e ( 1 3 ) w ith e c to rs . T 2 4 lb in c

th r o u m b ly th re ig h t e h ) .

g h ( 8 ) . e n

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3 . I f p r e s e n t , in s t a l l t w o b o l t s ( 1 3 6 ) a n d O L S a s s e m b l y ( 1 3 7 ) . T i g h t e n b o l t s t o 1 0 – 1 3 N ∙ m ( 7 – 1 0 l b f t ) . 4 . I n s t a l l t h e t u r b i n e s p e e d s e n s o r ( 9 4 ) , a n d t h e b o l t ( 9 3 ) . T i g h t e n b o l t t o 1 0 – 1 3 N ∙ m ( 7 – 1 0 l b f t ) . n . I n s t a l l a t i o n o f F i l t e r s ( F o l d o u t 1 5 - 1 , F o l d o u t 1 5 - 2 ) . 1 . I n s t a l l s u c t i o n fi l t e r ( 5 ) , g a s k e t ( 7 ) a n d f a c e s e a l ( 6 ) . I n s t a l l t h r e e b o l t s ( 3 ) . T i g h t e n b o l t s t o 1 0 – 1 3 N ∙ m ( 7 – 1 0 lb f t ) . 2 . I n s t a l l t w o fi l t e r s ( 1 6 2 ) , t w o O - r i n g s ( 1 6 1 ) , t w o O - r i n g s ( 1 6 0 ) , t w o g a s k e t s ( 1 5 9 ) , a n d t w o fi l t e r c o v e r s ( 1 5 8 ) . 3 . I f p r e s e n t a n d n o t p r e v i o u s l y i n s t a l l e d , i n s t a l l O L S a s s e m b ly ( 1 6 1 ) a n d t w o b o lt s ( 1 6 0 ) . T i g h t e n b o l t s t o 1 0 – 1 3 N ∙ m ( 7 – 1 0 lb f t ) .

C o p y r ig h t ©

2 0 0 9


5 - 6 5

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M A N U A L — 3 0 0 0 P r o d u c t F a m i l y — A l l i s o n 4 t h G e n e r a t i o n C o n t r o ls — V O C A T IO N A L M O D E L S N O T E S

5 - 6 6

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s e c tio n c o v ilie s t r a n s m e P o w e r T a k e a s s e m b ly c lu d e s a ll m

e rs th e is s io n s e o ff ( P s e q u e o d e l s .

a s s . A s T O ) n c e

e m b l y o f s e m b l y p r o v i s io n s is

b . P r o c e d u r e s . W h e n a p r o c e d u r e d o e s n o t a p p l y t o y o u r s p e c ifi c m o d e l , g o t o t h e n e x t a p p lic a b l e p r o c e d u r e . c . I l l u s t r a t i o n s . I l l u s t r a t i o n s w i l l n o t a l w a y s s h o w y o u r m o d e l , b u t w h e n a n o p e r a t i o n i i s i d e n t i c a l f o r a l l m o d e l s , t h e c o r r e c t p r o c e d u r e i s s h o w n . d G S g

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3 . M o u n t t h e fi x t u r e a n d m a in h o u s in g o n t h e r e p a ir s ta n d J – 2 9 1 0 9 . M a k e s u r e t h e m a in h o u s i n g c e n t e r l i n e i s h o r i z o n t a l . 4 . In s ta th r o u a lig n th e s

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l y ( 1 ) ( F ig u r e 6 – 1 ) m a i n h o u s i n g ( 2 ) , c h a s s e m b l y w i t h .

5 . I n s t a ll t w o M 1 0 X 1 . 5 X 3 5 m m b o lt s ( 3 ) , 1 8 0 d e g r e e s f r o m e a c h o t h e r , t o h o l d c lu t c h a s s e m b l y ( 1 ) in p l a c e . 6 . R h r T

o ta te th e re p a o u s in g o u t p u t e m a i n i n g t t e n M ig h te n a ll b o lts

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ir s ta n d s e n d is u p 1 0 X 1 . 5 to 5 1 – 6 1

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a n s m i s s io n s t a l l t h e m b o lt s ( 3 ) . 8 – 4 5 lb f t ) .

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b . In s ta lla t io n o f th e R o t a tin g ( F i g u r e 6 – 2 ) .

t s . R e f e r t o F o ld o u t 5 t h r o u g h - 2 f o r d i s a s s e m b l e d v ie w s a n d t h r o u g h F o l d o u t 3 8 f o r t h e h y d r a u l i c .

C l u t c h M o d u l e

1 . R o t a t e t h e r e p a ir s t a n d s o t h e in p u t e n d o f t h e m a i n h o u s in g i s u p .

A S S E M B L Y O F T R A N S M IS S IO N

2 . U s in g a h o is t a n d a n M 1 6 e y e b o lt , i n s e r t r o t a t i n g c l u t c h m o d u l e ( 1 ) i n t h e f r o n t o f t h e m a in h o u s in g .

A s s e m b l y o f C 3 /C 4 C l u t c h . 1 . M o u n t h o ld in g fi x t u r e J – 3 5 9 2 6 o n t o t h e m a in h o u s i n g .

C o p y r ig h t ©

2 0 0 9


6 - 1

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M A N U A L — 3 0 0 0 P r o d u c t F a m i l y — A l l i s o n 4 t h G e n e r a t i o n C o n t r o ls — V O C A T IO N A L M O D E L S d . I n s t a l l a t i o n o f t h e P 1 P l a n e t a r y M o d u l e ( F i g u r e 6 – 4 ) . 1 . R o t a t e t h e r e p a i r s t a n d s o t h e r e a r o f t h e m a in h o u s i n g is u p . 2 . I n s t a l l P 1 p l a n e t a r y m o d u l e ( 1 ) – c o n s i s t i n g o f t h e P 1 c a r r ie r a n d P 2 r in g g e a r . 3 . M e s h t h e P 1 p in io n g e a r s w it h t h e P 1 r in g g e a r in s id e t h e C 3 / C 4 c lu t c h a s s e m b l y .

F i g u r e 6 – 2 . R o t a t i n g C l u t c h M o d u l e I n s t a l l a t i o n c . I n s t a l l a t i o n o f t h e F r o n t S u p p o r t / C h a r g i n g P u m p M o d u l e ( F i g u r e 6 – 3 ) . 1 . L o w e r t h e f r o n t s u p p o r t a n d c h a r g in g p u m p m o d u l e ( 3 ) o v e r t h e t o p o f t h e t u r b i n e s h a f t . 2 . A l i g n t h e b o l t h o l e s i n t h e f r o n t s u p p o r t ( 3 ) w i t h t h e t h r e a d e d h o l e s in t h e m a i n h o u s in g . 3 . I n s t a ll s i x M 1 0 X 1 . 5 X 6 0 m m b o lt s ( 1 ) a n d fi v e M 1 0 X 1 .5 X 3 5 m m b o lt s ( 2 ) . T ig h t e n b o l t s t o 5 1 – 6 1 N ∙ m ( 3 8 – 4 5 lb f t ) .

F ig u re 6 – 4 .

P 1 P l a n e t a r y M o d u l e I n s t a l l a t i o n

e . I n s t a l l a t i o n o f t h e P 2 P l a n e t a r y M o d u l e ( F i g u r e 6 – 5 ) . 1 . I n s t a l l P 2 p l a n e t a r y m o d u l e ( 1 ) – c o n s i s t i n g o f t h e P 2 c a r r ie r a n d t h e P 3 r in g g e a r . 2 . M e s h t h e P 2 p in io n s w it h t h e P 2 r in g g e a r d u r i n g i n s t a l l a t i o n . f . I n s t a ll a t i o n o f t h e C 5 C l u t c h P a c k ( F i g u r e 6 – 5 ) . I I n s t a l l t h e C 5 c l u t c h p a c k i n t h e m a i n h o u s i n g — e i g h t s t e e l r e a c t i o n p l a t e s ( 2 ) a n d s e v e n f r i c t i o n p l a t e s ( 3 ) , s t a c k e d a l t e r n a t e l y , s t a r t i n g w i t h a s t e e l r e a c t i o n p l a t e . S t a c k a l l p l a t e s s o p l a t e c o n e f a c e s t h e s a m e d i r e c t i o n . S t e e l p l a t e s m e s h w i t h t h e m a i n h o u s in g a n d r e a c t i o n p l a t e s m e s h w it h t h e P 3 r in g g e a r .

F i g u r e 6 – 3 . F r o n t S u p p o r t / O i l P u m p M o d u l e I n s t a l l a t i o n

6 - 2

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2 0 0 9 A l l i s o n T r a n s m i s s i o n , I n n c .


A S S E M B L Y h . M a in S h a f t S e le c t i v e S h i m M e a s u r e m e n t F o r C l o s e R a t i o M o d e l s ( F i g u r e 6 – 7 ) . 1 . P l a c e a s t r a i g h t e d g e a c r o s s t h e r e t a r d e r o r r e a r c o v e r m o u n t in g s u r f a c e o f t h e m a in h o u s i n g . 2 . M e a s u r e d i m e n s i o n A , , f r o m t h e t o p o f t h e s t r a i g h t e d g e t o t h e s e l e c t i v e s h i m t h r u s t s u r f a c e o n t h e m a i n s h a f t b e a r in g s p a c e r . 3 . M e a s u r e d i m e n s i o n B B , , t h i c k n e s s o f s t r a i g h t e d g e . S u b t r a c t d i m e n s i o n B f r o m d i m e n s i o n A A – t h e r e m a i n d e r i s d i m e n s i o n C C . . 4 . P e a m a

F ig u r e 6 – 5 . P 2 P l a n e ta r y M o d u le a n d C l u t c h P a c k I n s t a l l a t i o n N O in in a s


g . In s ta lla In s ta ll m a in M O D U L E R a n d th ru s t b m o d e l s ) .

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re ta rd e r o r re a r c o v e r m o ( f a c in g t h e b e n c h t o p ) . p r e s s e d g a s k e t o n t h e s u r fa c e a n d p la c e a s tra P 3 p l a n e t a r y c a r r ie r .

d u le o u t p u t I n s t a l l r e t a r d e r i g h t e d g e

5 . M e a s u r e d i m e n s i o n D , , f r o m t h e t o p o f t h e s t r a i g h t e d g e t o t h e m o u n t in g g a s k e t . 6 . M s s d r


tio s h E B e a

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e a s u r e d i m e n s i o n E f r o m tra ig h te d g e to th e th r u s t b e u r fa c e o n th e P 3 p la n e ta r y i m e n s i o n E E f r o m d i m e n s i o e m a i n d e r i s d i m e n s i o n F F . .

th e to a r in g c a r r ie n D D –

p o f t h e c o n t a c t r . S u b t r a c t t h e

7 . D i m e n s i o n G i s t h e r e m a i n d e r o f C C m i n u s F a n d d e t e r m i n e s t h e t h i c k n e s s o f t h e s e l e c t i v e s h i m . 8 . In s ta l l t h e p r o p e r th i c k n e s s s e le c t iv e s h i m t h r u s t b e a r i n g .

a n d

F i g u r e 6 – 6 . M a i n S h a f t I n s t a l l a t i o n

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F ig u r e 6 – 7 . M a in

S h a ft S e le c tiv e S h im M e a s u r e m e n t (C lo s e R a tio 3 0 0 0 P r o d u c t F a m i l y E x c e p t 3 7 0 0 S P

i. M a in S h a f t S e le c t i v e S h i m M e a s u r e m e n t ( W i d e R a t i o M o d e l s ) ( F i g u r e 6 – 8 ) . 1 . P l a c e a s t r a i g h t e d g e a c r o s s t h e r e t a r d e r o r r e a r c o v e r m o u n t in g s u r f a c e o f t h e m a in h o u s i n g . 2 . M e a s u r e d i m e n s i o n A , , f r o m t h e t o p o f t h e s t r a i g h t e d g e t o t h e s e l e c t i v e s h i m t h r u s t s u r f a c e o n t h e m a i n s h a f t b e a r in g s p a c e r . 3 . M e a s u r e d i m e n s i o n B B , , t h i c k n e s s o f s t r a i g h t e d g e . S u b t r a c t d i m e n s i o n B f r o m d i m e n s i o n A A – t h e r e m a i n d e r i s d i m e n s i o n C C . . 6 - 4

C o p y r ig h t ©

4 . P d u r s

la c e r e t a r d e r o w n ( fa c in g th n c o m p re s s e d e a r c o v e r m o u tra ig h te d g e a c

M o d e ls ) –

o r re a r c o v e r o e b e n c h to p ) . g a s k e t o n th e n t in g s u r f a c e a r o s s th e P 3 p la

u t p u t e n d I n s t a l l a n r e t a r d e r o r n d p l a c e a n e t a r y c a r r i e r .

5 . M e a s u r e d i m e n s i o n D D f r o m t o p o f t h e s t r a i g h t e d g e t o t h e r e a r c o v e r m o u n t in g g a s k e t . 6 . M e a s u r e d i m e n s i o n E f r o m t h e t o p o f t h e s t r a i g h t e d g e t o t h e t h r u s t b e a r i n g c o n t a c t s u r f a c e o n t h e P 3 p l a n e t a r y c a r r i e r . S u b t r a c t



A S S E M B L Y

d i m e n s i o n s E f r o m d i m e n s i o n D D – t h e r e m a i n d e r i s d i m e n s i o n F F . . 7 . D i m e n s i o n G i s t h e r e m a i n d e r o f C C m i n u s F a n d d e t e r m i n e s t h e t h i c k n e s s o f t h e s e l e c t i v e s h i m . 8 . I n s t a l l t h e p r o p e r t h i c c k n e s s s e l e c t i v e s h i m t h r u s t b e a r i n g .

a n d

F ig u r e 6 – 8 . M a in S h a f t S e le c tiv e S h im j . M a in S h a f t S e le c t iv e S h i m 3 7 0 0 S P ( F i g u r e 6 – 9 ) .

M e a s u r e m e n t (W id e R a tio )―

M e a s u r e m e n t F o r

3 5 0 0 M o d e l

( g a s k e t r e m o v e d ) . A l s o , b e s u r e t h a t t h e r e i s n o s e l e c t iv e s h i m in p l a c e a t t h i s t im e .

1 . P la c e a s t r a i g h t e d g e a c r o s s t h e t r a n s f e r c a s e m o u n t in g s u r f a c e o f t h e a d a p t e r h o u s in g C o p y r ig h t ©

2 0 0 9


6 - 5

S E R V IC E


2 . M e a s u r e d i m e n s i o n A f r o m t h e t o p o f t h e s t r a i g h t e d g e t o t h e s h o u ld e r w h e r e t h e s e l e c t i v e s h i m w i l l r e s t . 3 . M e a s u re d im s tr a ig h t e d g e re s t s . S u b tra A – t h e r e m a

e n s io to th e c t d im in d e r

n B , , f fa c e e n s io is d im

r o m t h e t o p o f t h e w h e r e t h e g a s k e t n B B f r o m d i m e n s i o n e n s i o n C C . .

4 . P la c e tr a n s fe r c a s e r e a r o u t p u ( fa c in g t h e b e n c h to p ) . In s ta ll o n th e fr o n t m a in tr a n s fe r c a s s u r fa c e a n d p la c e a s tr a ig h te d t r a n s m i s s i o n s h a f t a d a p t e r .

t e a N e m g e

n d d o w E W g a o u n t in a c ro s s

n s k e t g t h e

5 . M e a s u r e d i m e n s i o n D f r o m t h e t o p o f t h e s t r a i g h t e d g e t o t h e t r a n s f e r c a s e m o u n t i n g g a s k e t . 6 . M s c d

e a s u r e d i m e n s io tra ig h te d g e to th e o u p lin g . S u b t r a c i m e n s i o n D D – t h e

n E f r o m s te p in s t d im e n s r e m a in d

th e to p id e th e i o n E f r e r is d im

o f t h e a d a p t e r o m e n s i o n F F . .

7 . D i m e n s i o n G i s t h e r e m a i n d e r o f C C m i n u s F , , a n d d e t e r m i n e s t h e t h i c k n e s s o f t h e s e l e c t i v e s h i m . 8 . C o a t t h e s e le c t e d s h im w i t h a g e n e r o u s c o a t i n g o f l u b e ( p e t r o l a t u m ) a n d i n s e r t t h e s h i m in s i d e t h e t r a n s m is s i o n s h a f t a d a p t e r .

6 - 6

C o p y r ig h t ©



F ig u r e 6 – 9 . M a in k .

S h a ft S e le c tiv e S h im

I n s t a l l a t i o n R e t a r d e r M o d u l e . W w c h

A R e ig a re a n d

N IN h s a to p lin g

G : T h e r e t a r d e r p p r o x im a t e ly 6 4 r e v e n t in ju r y t o p th e re ta r d e r m o d

1 . In s m a 1 .7 M 1 fo u T ig

t a ll rk e 5 x 2 b r M h te

fo u d A 1 9 o lts 1 0 n M

rte e n (F ig u 0 m m to 9 0 x 1 .5 1 0 b o

M 1 2 re 6 – m a rk – 1 1 0 x 1 8 2 lts to

x 1 .7 1 0 ). e d C N ∙m m m 5 1 – 6

m o k g e rs u le

d u le (1 4 1 o n n a s s

A S S E M B L Y

a s s e m b ly lb ) . U s e e l w h i l e e m b l y .

M e a s u r e m e n t 3 7 0 0 S P A ( ( N

ls o 9 4 ), F o ld ∙m

fo u r ju m o u t (3 8 –

M 1 p e r 1 1 A 4 5

0 x 1 . 5 x 1 9 2 m m b o l t s , g a s k e t m a n i f o l d ( 9 5 ) o r m a n i f o l d ( 9 6 ) ) . T ig h t e n M 1 0 b o l t s t o 5 1 – 6 1 lb f t ) .

2 . L u b r i c a t e a n d i n s t a l l o u t p u t s h a f t o i l s e a l ( 5 9 ) u s in g J – 3 9 9 2 8 - A .

5 x 1 3 0 m m b o lt s I n s t a ll f o u r M 1 2 x . T ig h te n e ig h te e n ( 6 6 – 8 1 lb f t ) . I n s t a l l b o lt s m a r k e d B . 1 N ∙ m ( 3 8 – 4 5 lb f t ) . C o p y r ig h t ©

2 0 0 9


6 - 7

S E R V IC E


F i g u r e 6 – 1 0 . R e t a r d e r M o d u l e B o l t s l. I n s t a ll a t i o n o f R e a r C o v e r M o d u l e ( F i g u r e 6 – 1 1 ) .

m . I n s t a l l a t i o n o f T r a n s f e r C a s e A d a p t e r H o u s i n g ( F i g u r e 6 – 1 2 ) .

1 . I n s t a l l a n e w r e a r c o v e r g a s k e t ( 1 ) o n m a i n h o u s i n g ( 4 ) . 2 . I n s t a l l g u i d e b o l t s t o e a s e r e a r c o v e r ( 2 ) in s t a l la t io n a n d k e e p g a s k e t ( 1 ) i n p l a c e . 3 . P l a c e r e a r c o v e r ( 2 ) o n m a i n h o u s in g ( 4 ) u s i n g a h o i s t a n d s l i n g a s a l i f t i n g fi x t u r e . I n s t a l l r e a r s u p p o r t b r a c k e t ( 3 ) ( F o l d o u t 1 1 B ) if u s e d . 4 . I n s ta ll n in e t e e n M 1 2 x 1 . 7 5 x 4 5 b o lt s ( 3 ) . T i g h t e n b o l t s t o 9 0 – 1 1 0 N ∙ m ( 6 6 – 8 1 lb ) . 5 . L u b r ic a t e a n d in s t a l l o u t p u t y o k e / fl a n g e o i l s e a l ( 5 ) u s i n g J – 3 9 9 2 8 - A . U s e J – 3 5 9 2 1 - 4 B f o r p a r k i n g b r a k e r e a r c o v e r m o d e l s .

6 - 8

C o p y r ig h t ©

F i g u r e 6 – 1 1 . R e a r C o v e r M o d u l e I n s t a l l a t i o n

1 . In s ta ll a n e w

a d a p t e r h o u s i n g g a s k e t ( 2 ) .

2 . I n s p e c t a d a p t e r h o u s i n g ( 3 ) f o r c r a c k s , n i c k s , o r b u r r s . R e m o v e t h e b u r r s a n d n i c k s w it h c r o c u s c l o t h o r s o f t s t o n e . 3 . In s ta M 1 2 1 .7 5 N ∙m

ll x x (6

4 . In M x (3

ll th r e x 1 .5 b o lts 4 5 lb

s ta 1 0 7 0 8 –

a d a 1 .7 6 0 6 – 8

p te r 5 x 4 b o lts 1 lb

h o 5 (5 ft)

u s i n g ( 3 ) b y i n s t a l l i n g fi f t e e n b o lt s ( 8 ) a n d t h r e e M 1 2 x ) . T o r q u e b o lt s t o 9 0 – 1 1 0 .

e M 1 0 x 1 . 5 x 1 0 0 b o l t s ( 6 ) , t w o x 4 0 b o lt s ( 7 ) , a n d f o u r M 1 0 x 1 . 5 ( 4 ) . T o r q u e b o l t s t o 5 1 – 6 1 N ∙ m f t ) .



F ig u r e

6 – 1 2 . T r a n s f e r C a s e A d a p t e r H o u s i n g I n s t a l l a t i o n

F i g u r e 6 – 1 3 . T r a n s f e r C a s e M o d u l e I n s t a l l a t i o n o . I n s t a l l a t i o n o f t h e C o n v e r t e r H o u s i n g M o d u l e ( F i g u r e 6 – 1 4 ) .

n . I n s t a l l a t i o n o f T r a n s f e r C a s e M o d u l e ( F i g u r e 6 – 1 3 ) . 1 . In s ta ll a n e w

1 . P l a c e t r a n s m i s s io n i n p u t e n d u p . I n s t a l l a n e w c o n v e r t e r h o u s in g g a s k e t ( 2 ) o n m a i n h o u s in g m o d u le ( 4 ) .

g a s k e t ( 4 ) .

2 . B e s u r e th a t s e le c tiv e s h im i n s i d e s h a f t a d a p t e r ( 5 ) .

( 1 ) i s lo c a t e d

2 . I n s t a l l g u i d e b o l t s t o e a s e c o n v e r t e r h o u s i n g ( 1 ) in s t a l la t io n a n d k e e p g a s k e t ( 2 ) i n p l a c e .

3 . M o u n t J – 3 8 5 7 2 o n t r a n s fe r c a s e ( 3 ) .

3 . L o w h o u e q u th e

W A R N I N G : T h e t r a n s f e r c a s e m o d u l e a s s e m b l y w e i g h t s a p p r o x im a t e l y 2 7 0 k g ( 5 9 5 l b ) . 4 . U s e h o i s t a n d J – 3 8 5 7 2 t o l i f t t r a n s f e r c a s e ( 3 ) . 5 . I n s t a l l t r a n s m i s s i o n s h a f t a d a p t e r ( 5 ) i n t o t r a n s f e r c a s e ( 3 ) . 6 . I n s t a l l t r a n s f e r c a s e ( 3 ) i n t o t h e m a i n t r a n s m is s io n , a n d i n s t a l l n i n e t e e n M 1 0 x 1 . 5 x 5 5 b o lt s ( 2 ) . 7 . In s ta ( 7 ) in a d a p 5 1 – 6

ll b o lt ) p a s te r h o 1 N ∙m

(2 7 ) o r s in g t h u s in g . (3 8 – 4

(2 8 ro u g T ig h 5 lb

A S S E M B L Y

e r s in ip p g e

4 . S ta rt ( 3 ) in U s e w h e n

c o n g (4 e d , a r ta

b y to m e in

v e rte ). If ro ta t n g s

r h o u s th e tra e th e P w it h th

in s ta llin g th e in s id e c h a n i c a l s t a l lin g th

in g ( 1 ) o n s m is s io T O d r iv e e c h a r g in

th re e M 1 o f c o n v e fi n g e r s , o e s e b o lts

n t n g g

o m is P e a r p u m

a i n T O t o a l i g n p .

0 x 1 . 5 x 3 5 b o l t s r t e r h o u s i n g ( 1 ) . r a s i m ila r t o o l, .

5 . R e m o v e t h e t w o g u i d e b o l t s a n d in s t a ll t h e r e m a in in g s e v e n t e e n M 1 0 x 1 . 5 x 3 5 b o lt s ( 3 ) . T i g h t e n a l l b o l t s t o 5 1 – 6 1 N ∙ m ( 3 8 – 4 5 lb f t ) .

) ( F o l d o u t 1 7 - 2 , b o l t h C 6 h o u s in g i n t o t h e t e n b o l t ( 2 7 ) o r ( 2 8 ) t o f t ) .

8 . T o r q u e n i n e t e e n b o l t s ( 2 ) t o 5 1 – 6 1 N ∙ m ( 3 8 – 4 5 l b f t ) .

C o p y r ig h t ©

2 0 0 9


6 - 9

S E R V IC E

M A N U A L — 3 0 0 0 P r o d u c t F a m i l y — A l l i s o n 4 t h G e n e r a t i o n C o n t r o ls — V O C A T IO N A L M O D E L S • I f t h e c o n t r o l v a l v e m o d u l e is in p l a c e , r e m o v e t h e p l u g ( s ) , i f p r e s e n t , f r o m t h e fi l l t u b e h o l e o r f r o m c o o l e r p o r t s b e f o r e a p p l y i n g l o c k u p a i r p r e s s u r e . A p p l y a i r p r e s s u r e t h r o u g h t h e lo c k u p p r e s s u r e t a p ( F ig u r e 4 – 7 , V ie w D ) a n d u s e a h e e l b a r , s c r e w d r i v e r , a n d b o l t s . I n s e r t t h e h e e l b a r i n t o a t o r q u e c o n v e r t e r h o u s i n g b o l t h o l e . I n s e r t t w o b o l t s i n t o t h e fl e x p l a t e a d a p t e r b o l t h o l e s . T h e n p l a c e a s c r e w d r iv e r a t a n a n g l e t o p r e v e n t c o n v e r t e r r o t a t io n ( F ig u r e 6 – 1 5 , V ie w C ) . 6 . I n s t a l l J – 3 8 5 4 8 C o n v e r t e r E n d P la y G a u g e a n d t i g h t e n t h e a t t a c h i n g b o l t t o 2 7 – 3 4 N ∙ m ( 2 0 – 2 5 l b f t ) .

F ig u r e 6 – 1 4 . C o n v e rte r H o u s in g I n s t a l l a t i o n

M o d u l e

p . I n s t a l l a t i o n o f t h e T o r q u e C o n v e r t e r M o d u l e ( F i g u r e 6 – 1 5 ) . 1 . T h e to rq u e c o n v e tu r b in e s h a ft w h ic s h a ft o r g ro u n d s g r o u n d s le e v e e n r a c e . T h e s p lin e s th e c o n v e rte r tu r b s h a ft is th r e a d e d c o n v e rte r re ta in in

r te r is in s h ro ta te s le e v e . T h g a g e th e o n th e tu in e . T h e a n d m a c h g b o lt a n d

2 . T h e s s h a ft s p lin e ta n g s th e c h d r iv e

g r o u n d s le e v e w it h th e ir r e u e c o n v e r t e r e rte r p u m p h u p ta n g s o r th e

p lin e s m u s t e s i n t t h o n th e a r g in g h u b .

o f th e n g a g e to r q c o n v p u m

t a l l e d o v e r t h e i n s i d e t h e s t a t o r e s p lin e s o n t h e c o n v e r t e r s t a t o r r b i n e s h a f t e n g a g e e n d o f t h e t u r b i n e i n e d t o a c c e p t t h e l o c k u p s e a l r i n g . e a n d t u r b i n e s p e c t iv e m o d u l e . T h e b m u s t e n g a g e P T O o il p u m p

3 . U s i n g a h o i s t a n d s l i n g , i n s t a l l t o r q u e c o n v e r t e r m o d u l e ( 6 ) i n t o t h e c o n v e r t e r h o u s i n g m o d u l e ( F ig u r e 6 – 1 5 , V ie w A ) . 4 . M a k e s e a te to e n p u m p

7 . M e a P la y it a s d im e J – 3 8 m m C F F i g 8 . U p J c c

s u r e f r o m t o p o f J – 3 8 5 4 8 C o n v e r t e r E n d G a u g e t o f a c e o f t u r b i n e s h a f t a n d r e c o r d d i m e n s i o n B B . . S u b t r a c t d i m e n s i o n B B f r o m n s i o n A A – d i m e n s i o n A A i s t h e h e i g h t o f 5 4 8 C o n v e r t e r E n d P la y G a u g e , 1 0 0 .0 0 ( 3 . 9 3 7 in c h ) t o d e t e r m in e d i m e n s io n u r e 6 – 1 5 , V ie w D ) .

s e D ro p e – 3 8 5 o n tin o n v e

9 . In s t s id e a n d ( F ig

im e n r s e le 4 8 C u e w r t e r .

a ll s to w J – 3 u re

e le c a rd 8 5 6 6 – 1

s i o n C a n c t iv e s h im o n v e rte r E it h in s t a l la t iv th 4 5 ,

s u r e t h e t o r q u e c o n v e r t e r is p r o p e r ly d . I f P T O e q u i p p e d , r o t a t e t h e P T O g e a r g a g e t h e p u m p h u b w it h t h e c h a r g in g .

• I n s e r t a s c r e w d r i v e r in t o t h e v a n e s o n t h e r o t a t i n g c l u t c h m o d u l e ( F ig u r e 6 – 1 5 , V ie w B ) .

C o p y r ig h t ©

le 6 n u m la y f th

– 1 to d b e r. R G a u g e e to rq u

e t e r m in e e m o v e a n d e

e s h i m ( 5 ) w i t h t h e s h i m s t e p e t u r b i n e s h a f t . I n s t a l l b o l t ( 4 ) C o n v e r t e r B o l t T ig h t e n i n g T o o l V ie w A ) .

N O T E : D D i m e n s i o n C s h o w n i n T a b l e 6 – 1 in c lu d e s a c o r r e c t io n d u e t o i n t e r n a l d e fl e c t i o n c a u s e d b y t h e 2 7 – 3 4 N ∙ m ( 2 0 – 2 5 l b f t ) b o l t t o r q u e a p p l i e d t o g a u g e P / N J 3 8 5 4 8 . A c c u r a t e t o r q u e v a lu e i s c r i t i c a l t o s e l e c t i o n o f t h e p r o p e r s h i m .

5 . H o l d t h e t u r b i n e a n d t u r b i n e s h a f t s t a t i o n a r y b y u s in g o n e o f t h e m e t h o d s lis te d b e lo w :

6 - 1 0

d T a b p a rt n d P t io n o



A S S E M B L Y

F ig u r e 6 – 1 5 . T o r q u e C o n v e r t e r M o d u le In s t a lla tio n a n d S e le c tiv e S h im

M e a s u r e m e n t

T a b l e 6 – 1 . T o r q u e C o n v e r t e r S e l e c t i v e S h i m s D im e n s io n

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0 .4 0 9 3 – 0 .6 5 9 7 m m

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2 9 5 0 5 6 8 8

0 .6 5 9 8 – 0 .8 3 7 7 m m

( 0 . 0 2 6 1 – 0 . 0 3 3 0 i n . )

2 9 5 0 5 6 8 1

0 .1 7 8 – 0 .2 2 8 m m

( 0 .0 0 7 – 0 .0 0 9 in .)

0 .8 3 7 8 – 1 .0 1 5 7 m m

( 0 . 0 3 3 1 – 0 . 0 4 0 0 i n . )

2 9 5 0 5 6 8 2

0 .3 5 6 – 0 .4 0 6 m m

( 0 .0 1 4 – 0 .0 1 6 in .)

1 .0 1 5 8 – 1 .1 9 3 7 m m

( 0 . 0 4 0 1 – 0 . 0 4 7 0 i n . )

2 9 5 0 5 6 8 3

0 .5 3 4 – 0 .5 8 4 m m

( 0 .0 2 1 – 0 .0 2 3 in .)

1 .1 9 3 8 – 1 .3 7 0 7 m m

( 0 . 0 4 7 1 – 0 . 0 5 4 0 i n . )

2 9 5 0 5 6 8 4

0 .7 1 1 – 0 .7 6 1 m m

( 0 .0 2 8 – 0 .0 3 0 in .)

1 .3 7 0 8 – 1 .5 4 8 7 m m

( 0 . 0 5 4 1 – 0 . 0 6 1 0 i n . )

2 9 5 0 5 6 8 5

0 .8 8 9 – 0 .9 3 9 m m

( 0 .0 3 5 – 0 .0 3 7 in .)

1 .5 4 8 8 – 1 .6 8 2 3 m m

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C o p y r ig h t ©

2 0 0 9

0 .0 0 0 m m


( 0 .0 0 0 in ) ; N O

S T E P

6 - 1 1

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1 0 . P r e v e n t t u r b i n e s h a f t r o t a t io n a s in S t e p 5 . T i g h t e n M 1 6 x 2 x 3 0 b o lt ( 4 ) t o 1 0 0 – 1 2 0 N ∙ m ( 7 4 – 8 9 lb f t ) ( F o l d o u t 1 8 - 2 ) . 1 1 . R e m o v T o o l. In e n d p lu in s t a ll t tig h t e n 1 2 . In (F to th (3

e J – 3 8 s ta ll O g (7 ). h re a d e it t o 5 0

5 6 4 - r in g U s e d c o – 6 0

C o n v e r te r B o lt (8 ) o n th r e a d e a 3 / 4 i n c h A l l e n n v e r te r e n d p lu N ∙m ( 3 7 – 4 4 lb

s ta ll c o n v e rte r s h ip p o ld o u t 8 - 1 ) , o r e q u iv r q u e c o n v e rte r to th e e s h ip p i n g b r a c k e t b 8 – 4 5 l b f t ) .

in g a le tra o lts

b r a c n t, to n s m to 5

T ig h d c o s o c g (7 f t ) .

k e ts re ta is s io n 1 – 6 1

te n n v e k e t ) a n

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a n d b le . H p a re u r in c u m p a p .

lu b o w a h s re

e fi lt e r s a e v e r, th e d iffe r e n t le u m p . T h e th e s a m e

r e fi l t e r s f o r a n g t h t h a n fi lt e r s in t h e a s in t h e

( 1 2 ) i n t h e . T i g h t e n N ∙ m

q . I n s t a l l a t i o n o f t h e C o n t r o l V a l v e M o d u l e ( F i g u r e 6 – 1 6 ) . W o v m p

A R v e rh e r tic o d u e rs o

N IN a u l a lly le . n a l

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d i n d a l v e u l t i n

1 . P o s i t i o n t r a n s m i s s i o n i n o v e r h a u l s t a n d v e r t i c a l l y . W a lb in c 3 lb

A R N I N G : T h e c o n t r o l v a l v e m o d u l e s s e m b ly w e ig h s a p p r o x im a t e ly 2 5 k g ( 5 6 ) . H a n d l e c a r e f u l ly t o a v o id p e r s o n a l ju r y o r c o n t r o l v a lv e m o d u le d a m a g e . T h e o n t r o l v a lv e m o d u l e a s s e m b ly u s e d in a 7 0 0 S P w e ig h s a p p r o x im a t e ly 2 9 k g ( 6 5 ) .

F i g u r e 6 – 1 6 . C o n t r o l V a l v e M o d u l e I n s t a l l a t i o n r.

2 . I n s t a l l a n e w c o n t r o l v a l v e m o d u le g a s k e t ( 2 ) o v e r t h e d o w e l p i n s o n c o n t r o l v a l v e m o d u l e ( 1 ) . 3 . G u i d e c o n t r o l v a lv e m o d u l e ( 1 ) o n t o t h e m a i n h o u s i n g u s i n g t h e d o w e l p i n s . I n s t a l l o n e b o l t ( 1 6 3 ) ( F o l d o u t 1 5 - 1 ) i n t h e t o p c e n t e r b o lt h o l e . 4 . In s ta ll tw o tw o g a s k e O - r in g s ( 1 r e m a in in g a n d /o r M 1 b o lts to 5 1

6 - 1 2

fi lte r c o v e r s ( 1 ts (1 5 9 ), tw o O 6 1 ) , a n d t w o fi th irty -o n e M 1 0 0 x 1 .5 x 1 0 0 b – 6 1 N ∙m (3 8 – 4

5 8 ) ( - r in g l t e r s x 1 .5 o lts ( 5 lb

F o s (1 x 1 6 ft)

ld o (1 6 6 2 ) 5 5 4 ). .

u t 1 5 0 ) , tw . In s b o lts T ig h

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I n s t a l l a t i o n o f P o w e r T a k e o f f ( s ) ( F i g u r e 6 – 1 7 ) . 1 . If r e m o v e d , in s ta ll P T O

s t u d s ( 4 ) .

2 . In s ta ll P In s e r t b 1 2 o ’c lo b o lts . T

n d P o f th s t a ll t 1 – 6 1

T O g a o lt ( 1 ) c k p o s ig h te n

- 1 ) , o t a l l ( 1 6 3 ) t e n a ll


s k e t (3 ) a in t o e a c h it io n s . I n b o lts to 5

T O a s s e e 6 o ’c lo h e re m a N ∙m (3 8

m b ly ( 2 ) . c k a n d i n i n g s i x – 4 5 lb f t ) .


F ig u r e

6 – 1 7 . P o w e r T a k e o f f ( s ) I n s t a l l a t i o n

s . I n s t a l l a t i o n o f I n t e g r a l O i l C o o l e r ( F o l d o u t 1 8 - 1 ) .

f t ) a n d t h r e e M 1 2 x 1 . 7 5 x 2 3 0 b o lt s ( 1 3 ) t o 1 0 0 – 1 2 0 N ∙ m ( 7 4 – 8 9 lf f t ) . 5 . L u b r i c a t e a n d i n s t a l l t h e O - r i n g s ( 2 8 ) o n t o c o o le r p l a t e a s s e m b l y ( 2 7 ) .

N O T E : • F o r u n i t s w i t h o u t r e t a r d e r , g o t o S t e p 1 . • F o r u n i t s w i t h r e t a r d e r , s k i p S t e p s 1 – 5 a n d g o to S t e p 6 . 1 . In s ta ll h o u s in In s ta ll (7 ) o n t a n d g a

th e g w th e o th s k e

A S S E M B L Y

tw o M 1 0 h e r e th e g a s k e t ( e g u id e t a re p ro

g u id e c o o le 5 ) a n d b o lts . p e r ly

s tu d r h o u th e B e s a lig n

s a t r s in g c o o le u re th e d .

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2 . I n s t a ll th e fi v e M 1 0 x 1 . 5 x 2 0 5 b o l t s ( 1 2 ) w it h n e w w a s h e r s ( 1 1 ) . 3 . R e m o v e t h e t w o M 1 0 g u id e s t u d s a n d in s t a ll t h e r e m a in in g t w o o r f o u r M 1 0 x 1 . 5 x 2 0 5 b o l t s ( 1 2 ) w it h n e w w a s h e r s ( 1 1 ) . 4 . I n s t a l l t h e t h r e e M 1 2 x 1 . 7 5 x 2 3 0 b o l t s ( 1 3 ) w it h n e w w a s h e r s ( 1 4 ) . T ig h te n t h e M 1 0 x 1 . 5 x 2 0 5 b o lt s ( 1 2 ) t o 5 1 – 6 1 N ∙ m ( 3 8 – 4 5 lb

C o p y r ig h t ©

2 0 0 9

N s S S P b b h u C o

O T E : B e g i n n i n g w i t h t r a n s m i s s i o n e r ia l n u m b e r s S / N 6 5 1 0 6 7 6 9 1 6 , / N 6 5 2 0 0 5 6 7 8 3 ( 7 P la t e C o o le r ) , / N 6 5 1 0 6 7 6 9 1 7 , S / N 6 5 2 0 0 5 8 8 1 0 ( 1 7 l a t e C o o l e r ) , t h e i n t e g r a l o i l c o o l e r h a s e e n r e d e s ig n e d t o u s e o n e t h ic k O - r in g e t w e e n t h e i n t e g r a l c o o l e r a n d t h e c o o l e r o u s in g . T h e c u r r e n t O - r in g c a n n o t b e s e d w i t h t h e f o r m e r in t e g r a l c o o l e r d e s i g n . u r r e n t n o n - s u m p i n t e g r a l c o o l e r s n o w u s e n l y o n e O - r in g in s t e a d o f t w o .

6 . I n s t a l l c o o l e r p l a t e a s s e m b l y ( 2 7 ) i n t o c o o l e r h o u s i n g ( 7 ) . 7 . L u b r ic M 1 0 g w h e re (2 2 ) a g u id e

a te a n u id e s c o v e r n d th e b o l t s .

d in s tu d s (2 3 ) c o v e


ta a a r

ll O t r e tta c (2 3

- r in g a r o f h e s . ) in t o

s (2 6 ). In c o o le r h o S lid e th e p o s itio n

s t a ll u s in g a s o v e r

t w o g k e t t h e

6 - 1 3

S E R V IC E


8 . I n s t a l l t h e t w o b o l t s ( 2 4 ) h a n d - t i g h t e n a t t h i s t i m e a n d t h e fi f t e e n b o l t s ( 2 5 ) ( h a n d - t i g h t e n a t t h i s t i m e ) .

W A R N IN s e c u r e ly p o s itio n b th e c o o le w e ig h s 1 h a n d lin g

9 . R e m o v e t h e t w o M 1 0 g u id e s t u d s a n d in s t a ll t h e r e m a i n i n g t w o b o lt s ( 2 5 ) . 1 0 . T i g h t e n t h e s e v e n t e e n b o l t s ( 2 5 ) t o 5 1 – 6 1 N ∙ m ( 3 8 – 4 5 lb f t ) . T i g h t e n t h e t w o b o l t s ( 2 4 ) t o 9 0 – 1 1 0 N ∙ m ( 6 6 – 8 1 lb f t ) . 1 1 . In s ta ll th (2 1 ) a n d T ig h t e n 5 1 – 6 1 N

e g th th e ∙m

a s k e e e ig e ig h (3 8 –

t ( h t t M 4 5

8 ), M 1 1 0 lb

G : T o s u p p o e fo re r to th 4 0 k g th e c o

h e lp a v o id p r t t h e c o o le r in s t a llin g th e e m a n ifo ld . ( 6 4 lb ) , u s e o l e r .

e rs o n a l in it s in s b o lt s r e T h e c o o c a re w h

i n j u r y , t a l l e d t a i n i n g l e r e n

1 1 . I n s t a l l c o o l e r p l a t e a s s e m b l y ( 7 ) t o c o o l e r m a n i f o l d ( 1 6 ) a n d r e t a i n w i t h s ix M 1 0 x 1 . 5 x 6 0 b o l t s ( 1 ) . T i g h t e n b o l t s fi n g e r - t i g h t .

t h e c o o l a n t p o r t s ( 9 ) o r 0 x 1 . 5 x 3 5 b o lt s ( 1 0 ) . x 1 . 5 x 3 5 b o l t s ( 1 0 ) t o f t ) .

1 2 . I n s t a l l g a s k e t s ( 3 ) a n d c o o la n t p o r t s ( 2 ) . 1 3 . R e re m th e (3 8

1 2 . L u b r i c a t e a n d i n s t a l l t h e O - r i n g s ( 2 6 ) o n t o t h e p r e s s u r e t a p s ( 1 8 ) . 1 3 . I n s t a l l t h e p r e s s u r e t a p s ( 1 7 ) i n t o c o o l e r h o u s i n g ( 7 ) . T i g h t e n t h e p r e s s u r e t a p s t o 1 0 – 1 3 N ∙ m ( 7 – 1 0 lb f t ) .

m o v a in te n – 4 5

e th e in g te M 1 0 lb f t)

t w o M 1 0 g u id e s tu d s a n d in s t a ll n M 1 0 x 1 . 5 x 6 0 b o l t s ( 1 ) . T o r q u e x 1 . 5 x 6 0 b o lt s ( 1 ) t o 5 1 – 6 1 N ∙ m .

1 4 . I n s t a l l s i x M 8 x 1 . 2 5 x 2 5 b o l t s ( 5 ) a a n d t o r q u e t o 2 4 – 2 9 N ∙ m ( 1 8 – 2 1 lb f t ) . 1 5 . L u b r i c a t e a n d i n s t a l l t h e O - r i nn g s o n p l u g s ( 1 2 ) , ( 2 6 ) , ( 1 4 ) , ( 1 8 ) , ( 2 1 ) , a n d ( 2 3 ) .

t . I n s t a l l a t i o n o f I n t e g r a l R e t a r d e r S u m p O i l C o o l e r ( F o l d o u t 1 8 - 2 ) . 1 . R o t a t e t h e t r a n s m is s io n s o t h e r e t a r d e r i s f a c i n g u p .

1 6 . I n s t a l l t h e p l u g a s s e m b l y ( 1 1 ) a n d t o r q u e t o 5 4 – 6 8 N ∙ m ( 4 0 – 5 0 lb f t )

2 . I n s t a ll t h e t w o M 1 0 g u i d e s tu d s in t o t h e t r a n s m i s s i o n h o u s i n g .

1 7 . I n s t a l l t h e p l u g a s s e m b l y ( 1 5 ) a n d ( 2 3 ) . T o r q u e t o 2 0 – 2 5 N ∙ m ( 1 5 – 1 8 lb f t )

3 . I n s t a l l th e g a s k e t ( 4 ) o v e r t h e M 1 0 g u id e s t u d s .

1 8 . I n s t a l l t h e p r e s s u r e t a p a s s e m b l y ( 2 5 ) , ( 2 0 ) , a n d ( 1 7 ) . T o r q u e t o 1 0 – 1 3 N ∙ m ( 7 – 1 0 lb f t ) .

4 . I n s t a l l t h e c o o l e r m a n i f o l d ( 1 6 ) o v e r t h e M 1 0 g u id e s t u d s . 5 . I n s t a ll t h e t h r e e M 1 2 x 1 . 7 5 x 2 1 8 b o l t s ( 8 ) . T i g h t e n b o l t s fi n g e r - t i g h t a t t h i s t i m e . 6 . R e m th e th e N ∙m

o v e ig e ig (3

e th h t M h t M 8 – 4

e tw 1 0 1 0 5 lb

I n s t a l l a t i o n o f S p e e d S e n s o r s . N O T E :

o M 1 0 g u i d e s t u d s a n d i n s t a l l x 1 . 5 x 2 1 0 b o lt s ( 9 ) . T o r q u e x 1 . 5 x 2 1 0 b o lt s ( 9 ) t o 5 1 – 6 1 f t ) .

7 . T o r q u e t h e t h r e e M 1 2 x 1 . 7 5 x 2 1 8 b o lt s ( 8 ) t o 9 0 – 1 1 0 N ∙ m ( 6 6 – 8 1 lb f t ) . 8 . R o t a t e t h e t r a n s m i s s io n s o t h e b r e a t h e r i s f a c i n g u p . 9 . I n s t a l l t w o M 1 0 g u i d e s t u d s in c o o l e r p l a t e a s s e m b l y ( 7 ) . 1 0 . I n s t a l l t w o g a s k e t s ( 6 ) o n t o c o o l e r p l a t e a s s e m b l y ( 7 ) .

6 - 1 4

u .

C o p y r ig h t ©

• F o r u n i t s w i t h o u t r e t a r d e r , g o t o S t e p 1 . • F o r u n i t s w i t h r e t a r d e r s k ip S t e p 1 a n d g o to S t e p 2 . 1 . In s ta ( F o ld M 8 x a s s e (3 2 ) N O T

ll o u t o u t 1 1 .2 5 m b ly to 2 4 E .

2 . In s ta ( F o ld M 8 x h o u s 2 4 – 2

ll o u o u t 1 .2 in g . 9 N

p u 1 A x (2 – 2

t s p ), O 2 0 1 ). 9 N

tp u t 1 1 B ) 5 x 2 T ig h ∙m (1


e e d - r in b o lt T ig h ∙m (

s e n s o r a g (3 0 ), re ( 3 2 ) in to te n M 8 x 1 8 – 2 1 lb

s p e e d s , O - r in g 0 b o lt ( te n M 8 8 – 2 1 lb

e n s o r a (4 0 ), re 4 2 ) in t o x 1 .2 5 x f t ) .

s s e ta in th e 1 .2 ft).

m b ly e r (3 re a r 5 x 2 S k ip

( 2 9 ) 1 ) , a n d c o v e r 0 b o lt t o n e x t

s s e ta in th e 2 0

m b e r re b o

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ly (4 ta lt


1 0 . I n s ta ll a n O - r in g ( 1 2 ) o v e r M 1 0 x 1 . 5 x 3 0 b o lt ( 1 0 ) , s o t h e O - r i n g s e a t s a g a i n s t t h e r e t a i n e r p l u g .

N O T E : • F o r m o d e ls w it h o u t P T O , g o t o S t e p 3 . • F o r m o d e ls w it h P T O , s k ip S t e p 3 a n d g o to S t e p 4 . 3 . In s ta ll in (F o ld o u t x 1 .2 5 x m o d u le . 2 4 – 2 9 N 4 . In s ta ( F o ld M 8 x h o u s (2 1 )

p u t 6 - 1 2 0 T ig ∙m

ll in p u t o u t 6 -2 1 .2 5 x in g m o to 2 4 – 2

s p e e d ) , O - r in b o lt ( 6 ) h te n M (1 8 – 2 1 s p e ), O 2 0 d u le 9 N

s e n s o r a s s e m g (4 ) , re ta in e r in t o th e c o n v e 8 x 1 .2 5 x 2 0 lb f t ) .

e d s e n s o r - r in g ( 1 9 ) , b o lt ( 2 1 ) in . T ig h te n M ∙m (1 8 – 2 1

b ly (5 ) , rte r b o lt

a s s e m b r e ta in e r to th e c 8 x 1 .2 lb f t ) .

( 3 ) a n d M 8 h o u s i n g ( 6 ) t o

ly ( 1 (2 0 ) o n v e 5 x 2

A S S E M B L Y

8 ) , a n d r t e r 0 b o lt

v . I n s t a l l a t i o n o f C o m m o n E x t e r n a l l y - M o u n t e d P a r t s ( F i g u r e 6 – 1 8 ) . 1 . I n s t a l l t r a n s m i s s i o n b r e a t h e r ( 2 6 ) , i f n o t p r e v i o u s l y i n s t a l l e d . T i g h t e n b r e a t h e r t o 1 2 – 1 6 N ∙ m ( 9 – 1 2 lb f t ) .

1 1 . I n s t a l l r e t a i n e r p l u g ( 1 1 ) i n t o t h e y o k e o r fl a n g e . T ig h t e n M 1 0 x 1 . 5 x 3 0 b o lt ( 1 0 ) t o 7 0 – 8 0 N ∙ m ( 5 2 – 5 9 lb f t ) . 1 2 . I f u s e d , i n s t a l l b r a k e d r u m ( 8 ) a n d e i g h t 3 / 8 – 2 4 x 3 / 4 b o l t s ( 9 ) . T i g h t e n b o l t s t o 5 6 – 6 6 N ∙ m ( 4 1 – 4 9 l b f t ) . N O T E : I f y o u h a v e a 3 7 0 0 S P m o d e l t r a n s m i s s io n , c o m p l e t e S t e p s 1 3 a n d 1 4 . R e f e r t o . 1 3 . R e p la c a n d in s M 1 0 x 5 1 – 6 1

e g a ta ll 1 .5 N .m

s k e t ( 9 ) ( t h i n c o a t e d m e t a l t y p e ) , s c a v e n g e p u m p ( 7 ) . I n s t a l l n i n e x 2 5 b o lt s ( 8 ) . T ig h t e n b o lt s t o ( 3 8 – 4 5 lb f t ) .

1 4 . I n s t a l l O - r i n g ( 4 ) a n d fi t t i n g ( 3 ) i n t o s c a v e n g e p u m p ( 7 ) . T ig h t e n ja m n u t t o 1 0 0 – 1 2 0 N ∙ m ( 7 4 – 8 8 l b f t ) .

2 . I n s t a l l fi l l t u b e s e a l ( 2 1 ) , fi l l t u b e ( 2 2 ) , b r a c k e t ( 2 4 ) , a n d s c r e w ( 2 3 ) . T i g h t e n s c r e w t o 2 4 – 2 9 N ∙ m ( 1 8 – 2 1 l b f t ) . I n s t a l l d i p s t i c k ( 2 5 ) . 3 . I n s t a l l s e a l ( 4 ) a n d p l u g ( 5 ) . P l u g ( 5 ) i s f u l l y s e a t e d w h e n t h e u n d e r s id e o f t h e p l u g h e a d c o n t a c t s s e a l ( 4 ) . 4 . I f t r a n s m is n e w c o o le c o o le r p o r x 3 5 b o lts ( 3 8 – 4 5 lb 5 . F o p o s ix to

r a rts , M 1 5 1 –

s io n h a s r e a r p o rt g a s k e t m a n ifo ld ( 1 ( 1 7 ) . T ig h t e f t ) .

tra n s in s t a 0 x 1 6 1 N

m i s s io n ll g a s k e .5 x 3 5 ∙m (3 8 –

r c t (2 9 ) n b

w h ic t (2 0 ) b o lts 4 5 lb

o o le 0 ). a n d o lts

r p In s s ix to

o rts ta ll M 1 5 1 –

, in re m 0 x 6 1

s t a l l o t e 1 . 5 N ∙ m

h u s e s f r o n t c o o l e r , c o v e r p l a t e ( 1 8 ) , a n d ( 1 7 ) . T i g h t e n t h e b o l t s f t ) .

6 . I n s t a l l p a r k i n g b r a k e a s s e m b l y ( 6 ) . I n s t a l l f o u r M 1 6 x 2 x 4 0 b o l t s ( 7 ) . T i g h t e n b o l t s t o 2 2 8 – 2 6 6 N ∙ m ( 1 6 8 – 1 9 6 lb f t ) . 7 . I n s t a l l o u t p u t fl a n g e ( 1 4 ) o r y o k e ( 1 5 ) , a n d s l i n g e r ( 1 6 ) i f a p p l i c a b l e . 8 . I n s t a l l l u b r i c a t e d O O - r i n g ( 1 3 ) o n r e t a i n e r p l u g ( 1 1 ) . 9 . I n s e r t M 1 0 x 1 . 5 x 3 0 b o l t ( 1 0 ) t h r o u g h r e t a i n e r p l u g ( 1 1 ) .

C o p y r ig h t ©

2 0 0 9


6 - 1 5

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F ig u r e 6 – 1 8 . E x t e r n a lly - M o u n te d

6 - 1 6

C o p y r ig h t ©

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A S S E M B L Y

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2 4 3 k g ( 5 3 5 lb s )

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m o (F i is s n d N T R tr th

v a l o f T ra n s m g u r e 6 – 2 0 ) . U io n a n d h o ld i n g p re p a re fo r v e

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n F r o m R e p a i r a h o i s t, r e m o v e t h e r e f r o m t h e r e p a i r i n s t a l l a t i o n .

3 – 1 1 . E N G IN E , A D A P T A T IO N S f o r p r e p a r in g t h e i n s t a l l a t i o n a n d i n s t a l l i n g i n t o t h e v e h i c l e .

C A U T I O N : W h e n e v e r a t r a n s m i s s i o n i s o v e r h a u le d , e x c h a n g e d , o r h a s u n d e r g o n e r e p a i r s , t h e T r a n s m i s s i o n C o n t r o l M o d u l e ( T C M ) m u s t b e “ R E S E T T O U N A D A P T E D S H I F T S ” . T h i s w ill c a u s e t h e T C M t o e r a s e p r e v i o u s a d a p t i v e i n f o r m a t i o n a n d b e g i n t o a d a p t i n F a s t A d a p t iv e M o d e f r o m t h e b a s e c a l i b r a t i o n . U s e t h e A l l i s o n D O C ® F o r P C – S e r v i c e T o o l ( r e f e r t o t h e A l l i s o n D O C ® U s e r ’ s G u i d e f o r i n s t r u c t i o n s ) t o “ R E S E T T O U N A D A P T E D S H I F T S ” .

C o p y r ig h t ©

2 0 0 9


6 - 1 7

S E R V IC E


F ig u r e 6 – 2 0 . R e m o v in g

6 - 1 8

C o p y r ig h t ©

T ra n s m is s io n

F r o m

R e p a ir S t a n d


S E C T IO N 7 – 1 .

W E A R

a . M a x im in t h is s e c c o m p o n e n T a b le 7 – 1 th e d is a s s F o ld o u t 1 9 b . C to p e R e fe IN F O

.

g a fe c t c tio IO N

S p r in g R e l a c e d if th e to ru b b in g c a r d s p r in g c ifi c a t io n s

e p u e is p e

b a a k F

. In s p e c n d id e n tifi re p re s e n e y e d to th o ld o u t 1 9 N n r P u

L IM IT S

A N D

S P R IN G

D A T A

r lim u m c t io a ta t 5 m a

it s in f o r m a w e a r a t w h n s a tis f a c t o a n d re fe re t h r o u g h n u a l.

t i o n ic h r i l y . n c e s

n d I n s p e c t i o n . P P a r t s m u s t b e c l e a n iv e in s p e c t io n f o r w e a r o r d a m a g e . n 3 . G E N E R A L O V E R H A U L .

S P R IN G

a r d D s

W E A R

D A T A

u m V a r i a t i o n s . W W e a t i o n s h o w s t h e m a x im ts a re e x p e c te d to fu n lis ts t h e W e a r L im its D e m b l e d v ie w s ( F o l d o u - 2 ) in th e b a c k o f t h is

le a n in r m it e f r to S e R M A T

7 – 2 .

L IM IT S

7 —

p la c e re a re a d ja c s w h ic a c c o rd

D A T A m e s ig e n t h d in g

n t . S n s o f p a r ts o n o t to T a

p r in o v e , o r m e b le

g s s h o u r h e a t in g p e rm a n e t t h e lo 7 – 2

ld b e , w e a r e n t s e t . a d h e i g h t

t i o n . I I n s p e c t i o n c r i t e r i a ( l o a d v c a t io n c h a r a c t e r is t ic s o f t h e s p te d in T a b le 7 – 2 . T h e S p r in g D e d i s a s s e m b l e d v ie w s ( F o l d o u t - 2 ) in t h e b a c k o f t h i s m a n u a l.

s . h e i g h t ) r i n g s a t a a r e 5 t h r o u g h

O T E : W h e n m o r e t h a n o n e s p r i n g p a r t u m b e r is lis t e d f o r t h e s a m e lo c a t io n , e f e r t o t h e l a t e s t e d i t i o n o f P a r t s C a t a l o g C 2 1 5 0 E N t o d e t e r m in e w h ic h s p r in g is s e d i n y o u r s p e c i fi c a s s e m b l y n u m b e r .

T a b le Illu s tr a tio n

7 – 1 . W e a r L im its

D a t a

D e s c r ip tio n

W e a r L i m it m m

F o l d o u t 5 8

T O R Q U E

C O N V E R T E R

B u s h in g , M a x im u m

M O D U L E

ID

6 1 .5 1

( 2 . 4 2 2 )

5 .7 1

( 0 . 2 2 5 )

D i s to r tio n

0 .5 1

( 0 .0 2 0 )

T h ic k n e s s , P e r S id e

0 .6 2 5

( 0 .0 2 5 )

0 .3 8

( 0 .0 1 5 )

1 0

L o c k u p P is t o n , M in im u m

1 2

L o c k u p C lu t c h F r ic t io n P l a t e F la t n e s s , M a x im u m

1 2

L o c k u p C l u tc h F r ic tio n P la t e , M in im u m

1 2 , 1 7

( in c h e s )

T h ic k n e s s

T u r b in e - T o - D a m p e r S p lin e W e a r, M a x im u m

M o v e m e n t

1 3

L o c k u p C l u t c h B a c k p l a t e , M a x i m u m C o n e

0 .1 5

(0 .0 0 6 )

1 4

L o c k u p C l u t c h B a c k p l a t e W e a r S u r f a c e , M i n i m u m T h i c k n e s s

8 .5 8

( 0 . 3 3 8 )

C o p y r ig h t ©

2 0 0 9


7 - 1

S E R V IC E

M A N U A L — 3 0 0 0 P r o d u c t F a m i l y — A l l i s o n 4 t h G e n e r a t i o n C o n t r o ls — V O C A T IO N A L M O D E L S T a b le

7 -1 . W e a r L im its

Illu s tr a tio n

D a t a ( ( c o n t ’ d )

D e s c r ip tio n


1 5

T u r b in e H u b H o o k - T y p e S e a lr in g , M a x im u m I n s t a l l e d I n C o v e r ( 7 ) B o r e

1 7

T o r q u e C o n v e r t e r T u r b in e H u b , M in im u m

2 2

S t a t o r T h r u s t P l a t e , M in i m u m

2 3

S t a t o r T h r u s t W a s h e r , M a x i m u m S u r f a c e

3 3

T o r q u e C o n v e r te r P u m p H u b , M in im u m

F o l d o u t 6 - 2

C O N V E R T E R

W h e n

O D

T h ic k n e s s

H O U S IN G

7

B e a r in g R e ta in e r B o r e , M a x im u m

U n w o r n

O D

( 2 . 2 3 4 )

6 1 .3 4

(2 .4 1 5 )

0 .2 5

( . 0 1 0 )

7 4 .9 9 ( 2 .9 5 2 )

M O D U L E

B e a r in g R e ta in e r B u s h in g , M a x im u m

5 6 .7 5

1 1 .6 8 ( 0 .4 6 0 )

S te p W e a r F ro m

6

—

W IT H

ID

I D

7 5 .2 3

( 2 . 9 6 2 )

1 4 0 .0 6

( 5 . 5 1 4 )

1 0 , 1 6

P T O G e a r A s s e m b ly S e a ls , W h e n I n s t a ll e d i n S e a lin g B o r e , M in im u m E n d G a p

0 .5 7

( 0 . 0 2 2 )

1 0 , 1 6

P T O G e a r A s s e m b ly D r i v e H u b S e a ls , W h e n I n s t a lle d in S e a lin g B o r e , M a x im u m E n d G a p

1 .1 5

( 0 . 0 4 5 )

1 3

O il P u m p D r iv e H u b , M a x im u m

0 .3 8 ( 0 .0 1 5 )

2 2

C o n v e r te r H o u s in g B e a r in g B o r e , M a x im u m

F o l d o u t 7 - 1

F R O N T S U P P O R T A N D

T a n g W e a r

C H A R G IN G

ID

1 4 0 .0 3

(5 .5 1 3 )

7 5 .2 3

( 2 . 9 6 2 ) (0 .7 0 6 )

P U M P M O D U L E

8

P u m p H o u s in g B u s h in g , M a x im u m

9

P u m p H o u s in g G e a r C a v it y , M a x im u m

D e p th

1 7 .9 3

9

P u m p H o u s in g G e a r C a v it y , M a x im u m

ID

1 2 7 .3 0 ( 5 .0 1 2 )

9 , 1 0

ID

D r i v e n G e a r - T o - P u m p H o u s i n g , M a x i m u m C l e a r a n c e

1 0

D r iv e /D r iv e n G e a r, M a x im u m

1 0

D r iv e n G e a r, M in im u m

1 0

D r iv e / D r iv e n G e a r , M in im u m

1 0 , 1 4

D ia m e t r ic a l

0 .3 6

( 0 . 0 1 4 )

G e a r T o o th T ip C le a r a n c e

0 .2 0

( 0 .0 0 8 )

O D

G e a r - T o - P la te M a x im u m

W

id t h

S id e C le a r a n c e

1 1

P u m p D r iv e G e a r B u s h in g , M a x im u m

1 4

W e a r P la t e , M i n i m u m

1 6 , 1 7

(4 .9 9 8 )

1 7 .8 1

(0 .7 0 1 )

0 .1 3 ( 0 .0 0 5 )

ID

5 7 .3 0 (2 .2 5 6 )

T h ic k n e s s

G r o u n d S le e v e O i l P u m p B u s h i n g J o u r n a l , M in im u m

1 2 6 .9 5

O D

4 .7 0

( 0 . 1 8 5 )

5 7 .0 4

( 2 .2 4 6 )

9 8 .8 3

(3 .8 9 1 )

2 0

F r o n t S u p p o r t S le e v e , M in im u m

2 3

F r o n t S u p p o r t S e a l, M in im u m

E n d G a p

0 .5 7

(0 .0 2 2 )

2 3

F r o n t S u p p o r t S e a l, M a x im u m

E n d G a p

1 .4 4

(0 .0 5 7 )

F o l d o u t 7 - 2 7

7 - 2

T O R Q U E P T O

ID

( in c h e s )

R O T A T IN G

C L U T C H

D im e n s io n

M O D U L E

T u r b in e S h a ft B u s h in g ID , M a x im u m

2 0 .1 9

(0 .7 9 5 )

1 0

T u r b in e S h a ft S e a l, M in im u m

E n d G a p

0 .4 6

(0 .0 1 8 )

1 0

T u r b in e S h a ft S e a l, M a x im u m

E n d G a p

0 .9 4

(0 .0 3 7 )

1 1

D r u m , M a x im u m

0 .3 8

(0 .0 1 5 )

S p lin e W e a r

C o p y r ig h t ©


W E A R T a b le

L IM IT S

A N D

S P R IN G


Illu s tr a tio n

D A T A

D a t a ( ( c o n t ’ d )

D e s c r ip tio n


1 3

R o t a t in g C lu tc h H u b B u s h in g , M a x im u m

ID

2 9

C 1 C lu tc h A p p ly P la te F la tn e s s , M a x im u m

2 9

C 1 C l u t c h A p p l y P l a t e , M i n i m u m

3 2

C 1 C lu t c h B a c k in g P l a t e , M in i m u m

( in c h e s )

9 9 .2 5 ( 3 .9 0 7 ) D is t o r tio n

T h ic k n e s s T h ic k n e s s

0 .1 5

( 0 .0 0 6 )

4 .2 0

(0 .1 6 5 )

8 .2 0

(0 .3 2 3 )

3 0 , 3 8

C 1 , C 2 F r ic tio n P la t e , M a x im u m

3 0 , 3 8

C 1 , C 2 F r ic t io n P la t e , M in im u m

T h ic k n e s s

2 .2 1

(0 .0 8 7 )

3 0 , 3 8

C 1 , C 2 F r i c t i o n P la t e , M i n i m u m

O il G r o o v e D e p t h

0 .2 0

(0 .0 0 8 )

3 1 , 3 7

C 1 , C 2 S te e l R e a c tio n P la te , M a x im u m

0 .4 0

(0 .0 1 6 )

3 1 , 3 7

C 1 , C 2 S t e e l R e a c t io n P la t e , M i n im u m

2 .3 6

(0 .0 9 3 )

3 4 , 3 6

C 1 , C 2 D r iv e H u b , M a x im u m

C o n e

0 .4 0 (0 .0 1 6 )

C o n e T h ic k n e s s

S p lin e W e a r

3 9

C 2 C lu t c h P r e s s u r e P la t e , M a x im u m

3 9

C 2 C lu t c h P r e s s u r e P l a t e , M i n i m u m

4 3

P 1 S u n G e a r D r iv e H u b B u s h in g , M a x im u m

F o l d o u t 8 - 1

M A IN

H O U S IN G

0 .3 8 ( 0 .0 1 5 )

C o n e

0 .4 5 ( 0 .0 1 8 )

T h ic k n e s s

6 .2 5

ID

(0 .2 4 6 )

6 8 .2 2 ( 2 .6 8 5 )

M O D U L E

4

C 3 B a c k p la te P la te F la tn e s s , M a x im u m

D is t o r t io n

0 .1 5

(0 .0 0 6 )

4

C 3 B a c k p la t e P la t e F la t n e s s , M a x im u m

S te p W e a r

0 .1 3

(0 .0 0 5 )

5 , 1 6

C 3 , C 4 W

e a r P la t e F la t n e s s , M a x im u m

D is t o r t io n

6 8 .2 2

(0 .0 0 6 )

5 , 1 6

C 3 , C 4 W

e a r P la t e , M i n i m u m

2 .8 1

(0 .1 1 1 )

0 .3 8

(0 .0 1 5 )

0 .4 0

( 0 .0 1 6 )

7 7 , 1 5 , 2 9

P 1 R in g G e a r , M a x im u m

T h ic k n e s s A t W e a r P o in t

S p lin e W e a r

C 3 , C 4 , C 5 F r ic t io n P la t e C o n e , M a x i m u m

D is t o r tio n

7 , 1 5

C 3 , C 4 F r ic t io n P la t e , M in im u m

T h ic k n e s s

2 .2 1

(0 .0 8 7 )

7 , 1 5

C 3 , C 4 F r ic t io n P l a te , M a x im u m A r o u n d L u b r i c a t i o n S l o t s

F r ic tio n M a te r ia l E r o s io n

4 .0 0

( 0 . 1 5 7 )

7 , 1 5

C 3 , C 4 F r ic t io n P la t e , M i n im u m

0 .2 0

(0 .0 0 8 )

0 .4 0

( 0 .0 1 6 )

3 .2 0

(0 .1 2 6 )

2 .3 6

(0 .0 9 3 )

0 .4 0

( 0 .0 1 6 )

3 .4 1

(0 .1 3 5 )

0 .1 5

( 0 .0 0 6 )

1 .1 5

(0 .0 4 5 )

8 , 1 4 , 2 8 8 , 1 4 2 8

O il G r o o v e D e p th

C 3 , C 4 , C 5 R e a c t io n S t e e l P la te C o n e , M a x im u m C 3 , C 4 R e a c tio n S te e l P la t e , M in im u m C 5 R e a c t io n S te e l P la t e , M in im u m

D i s to r t io n

T h ic k n e s s

T h ic k n e s s

9 , 1 6

C 3 , C 4 P is t o n R e t u r n P la t e C o n e , M a x i m u m

9 , 1 6

C 3 , C 4 P i s t o n R e t u r n P la t e , M i n i m u m

1 3 , 1 8

C 3 , C 4 C lu tc h H o u s in g F la t n e s s , M a x im u m

D is to r t io n

T h ic k n e s s D is to r t io n

2 2

M a in H o u s in g C lu t c h P la t e S p lin e s , M a x im u m

2 8

C 5 F r ic t io n P la t e , M in im u m

T h ic k n e s s

2 .9 0 ( 0 .1 1 4 )

2 8

C 5 F r ic tio n P la t e , M in im u m


0 .2 0

(0 .0 0 8 )

0 .3 8

(0 .0 1 5 )

1 9 .9 8

(0 .7 8 7 )

F o l d o u t 8 - 2 , F o l d o u t 9 - 1

M A IN

W e a r

S H A F T M O D U L E ( 3 0 0 0 , 3 5 0 0 )

N A

M a in S h a f t S p in e s M a x im u m

9 , 8

M a in S h a ft P ilo t , M in im u m

C o p y r ig h t ©

W

e a r

O D

2 0 0 9


7 - 3

S E R V IC E

M A N U A L — 3 0 0 0 P r o d u c t F a m i l y — A l l i s o n 4 t h G e n e r a t i o n C o n t r o ls — V O C A T IO N A L M O D E L S T a b le


Illu s tr a tio n

D a t a ( ( c o n t ’ d )

D e s c r ip tio n


9 , 8 F o l d o u t 9 - 2 N A

M A IN

S H A F T M O D U L E

O D

4 2 .9 7

(1 .6 9 2 )

0 .3 8

(0 .0 1 5 )

( 3 7 0 0 S P )

M a in S h a ft S p in e s M a x im u m

W

e a r

8

M a i n S h a f t P i l o t ( F r o n t ) , M i n i m u m

8

M a in S h a f t P 2 B u s h in g J o u r n a l, M in im u m

O D

4 2 .9 7

(1 .6 9 2 )

8

M a in S h a f t C 6 B u s h in g J o u r n a l, M in im u m

O D

3 5 .9 2

(1 .4 1 4 )

8

M a in S h a f t P 3 B u s h in g J o u r n a l, M in im u m

O D

5 2 .9 8 ( 2 .0 8 6 )

F o l d o u t 1 0 - 1

O D

1 9 .9 8 ( 0 .7 8 7 )

P 1 P L A N E T A R Y M O D U L E

9 , 1 2

P 1 P in io n T h r u s t W a s h e r, M in im u m

T h ic k n e s s

1 .3 9

( 0 . 0 5 4 )

9 , 1 2

P 1 P i n i o n T h r u s t W a s h e r , M a x i m u m

S te p W e a r

0 .1 2

(0 .0 0 5 )

0 .9 4

( 0 . 0 3 7 )

0 .3 8

(0 .0 1 5 )

4 3 .2 0

(1 .7 0 1 )

1 0

P in io n , M a x im u m

1 4

P 2 R in g G e a r, M a x im u m

F o ld o u t 1 0 - 2 6

E n d P la y S p lin e W e a r

P 2 P L A N E T A R Y M O D U L E P 2 C a r r ie r B u s h in g , M a x im u m

ID

7 , 1 0


T h ic k n e s s

1 .3 9

( 0 . 0 5 4 )

7 , 1 0

P 2 P in io n T h r u s t W a s h e r, M a x im u m

S te p W e a r

0 .1 2

(0 .0 0 5 )

0 .9 4

( 0 . 0 3 7 )

0 .3 8

(0 .0 1 5 )

2 0 .1 9

(0 .7 9 5 )

9 1 4 F o ld o u t 1 1 A

P in io n , M a x im u m

E n d P la y

P 3 R i n g G e a r , M a x i m u m R E T A R D E R

A N D

S p lin e W e a r


8

O u tp u t S h a f t B u s h in g , M a x im u m

9

O u tp u t S h a f t, M a x im u m

ID

S p lin e W e a r

0 .3 8

(0 .0 1 5 )


T h ic k n e s s

1 .3 9

(0 .0 5 4 )

1 6 , 1 9


S te p W e a r

0 .1 2

(0 .0 0 5 )

0 .9 4

( 0 . 0 3 7 )

2 9 , 3 2 3 1 F o l d o u t 1 1 B

P 3 P in i o n , M a x i m u m

E n d P la y

R e ta r d e r R o to r S e a lr in g , M a x im u m R o to r H u b , M a x im u m R E A R

C O V E R

A N D

ID

0 .3 8

(0 .0 1 5 )

2 0 .1 9

(0 .7 9 5 )

0 .3 8

(0 .0 1 5 )

P 3 P L A N E T A R Y M O D U L E

O u tp u t S h a f t B u s h in g , M a x im u m

8

O u t p u t S h a f t , M a x i m u m

ID

S p lin e W e a r

1 7 , 2 0


T h ic k n e s s

1 .3 9

( 0 . 0 5 4 )

1 7 , 2 0


S te p W e a r

0 .1 2

(0 .0 0 5 )

0 .9 4

( 0 . 0 3 7 )

F o ld o u t 1 3

P 3 P in i o n , M a x i m u m C 7 C L U T C H

9 5 .6 7 ( 3 .7 6 7 )

S p lin e W e a r

7

1 8

M O D U L E

1 6 , 1 9

1 7

7 - 4

M a in S h a f t P 2 B u s h i n g J o u r n a l, M in i m u m

( in c h e s )

E n d P la y

H O U S IN G

4 4

Y o k e J o u r n a l S e a l W e a r , M in i m u m

6 1

C 7 B a c k p l a t e , M i n i m u m

6 2

C 7 F r ic tio n P la te , M in im u m

C o p y r ig h t ©

D ia m e te r

T h ic k n e s s T h ic k n e s s


7 6 .2 0 ( 3 .0 0 0 ) 8 .6 7

(0 .3 4 1 )

2 .2 1 ( 0 .0 8 7 )

W E A R

L IM IT S

T a b le

A N D

S P R IN G


Illu s tr a tio n

D A T A

D a t a ( ( c o n t ’ d )

D e s c r ip tio n


6 2

C 7 F r i c t i o n P l a t e , M in im u m

6 2

C 7 F r ic tio n P la te , M a x im u m

6 3

C 7 R e a c tio n P la te , M in im u m

T h ic k n e s s

2 .0 6 ( 0 .0 8 1 )

6 3

C 7 R e a c tio n P la te , M a x im u m

C o n e

0 .2 5

(0 .0 1 0 )

6 8

B u s h in g , M a x im u m

4 7 .2 6

( 1 . 8 6 1 )

6 9

B a ll, F r e e M o v e m e n t

1 .0 0

( 0 . 0 4 0 )

7 .9 0

( 0 . 3 1 1 )

0 .4 0

(0 .0 1 6 )

F o ld o u t 1 4

C 6 C L U T C H


( in c h e s )

C o n e

ID

0 .2 0

(0 .0 0 8 )

0 .2 5

(0 .0 1 0 )

H O U S IN G

9

B a c k p la t e , M in im u m

9

B a c k p la t e , M a x im u m

T h ic k n e s s C o n e

1 0

C 6 F r ic t io n P la t e , M in im u m

T h ic k n e s s

3 .6 8

(0 .1 4 5 )

1 0

C 6 F r ic tio n P la t e , M in im u m


0 .2 0

(0 .0 0 8 )

1 1

C 6 R e a c tio n P la te , M in im u m

T h ic k n e s s

2 .3 6 ( 0 .0 9 3 )

1 1

C 6 R e a c tio n P la te , M a x im u m

C o n e

0 .4 0

(0 .0 1 6 )

1 9

C 6 H o u s in g , M a x im u m

2 .2 9

(0 .0 9 0 )

2 1

C 6 H o u s i n g B u s h i n g

3 6 .1 8

(1 .4 2 4 )

5 3 .2 2

(2 .0 9 5 )

F o ld o u t 1 7 - 2 6

T R A N S F E R C A S E M O D U L E

G ro o v e W e a r

A D A P T E R

P 3 C a r r ie r B u s h in g , M a x im u m

H O U S IN G

A N D

P 3

ID

8 , 1 1

P 3 P in io n T h r u s t W a s h e r , M in im u m

T h ic k n e s s

1 .3 9

( 0 . 0 5 4 )

8 , 1 1


S te p W e a r

0 .1 2

(0 .0 0 5 )

0 .9 4

( 0 . 0 3 7 )

2 .4 7

(0 .0 9 7 )

9 F o l d o u t 1 9 - 1 1 6

P i n i o n , M a x i m u m

E n d P la y

S C A V E N G E P U M P S c a v e n g e P u m p T h r u s t W a s h e r, M in im u m

C o p y r ig h t ©

2 0 0 9

T h ic k n e s s


7 - 5

7 6-

T a b le F o l d o u t


R e f.

S p r in g

P a r t N o .

7 – 2 . S p r in g

C o l o r N o . C o i l s C o d e

D a t a

W i r e D i a . m m ( i n . )

A p p r o x . S p r i n g O D F r e e L e n g t h m m ( i n . ) m m ( i n . )

F o ld o u t 5

2 5

S t a t o r

2 9 5 0 0 0 6 4

N o C o d e

N /A C o n v o l u t e d

F o l d o u t 7 - 2

2 1

C 2 R e t u r n S p r i n g A s s e m b l y

2 9 5 0 3 2 1 5

N o C o d e

1 2 *

2 . 0 4 ( 0 . 0 8 0 ) *

1 3 . 0 0 ( 0 . 5 1 2 ) *

F o l d o u t 7 - 2

2 5 C 1 R e t u r n S p r i n g A s s e m b l y

2 3 0 4 5 5 8 6

N o C o d e

1 0 *

2 . 1 9 ( 0 . 0 8 6 ) *

F o ld o u t 8 - 1

1 0

C 3 R e tu r n

2 9 5 0 5 5 7 0

N o C o d e

1 1 *

F o ld o u t 8 - 1

2 0

C 4 R e tu r n

2 9 5 0 5 5 7 0

N o C o d e

N /A

N /A

1 7 .8 (0 .7 0 )

L e n g t h U n d e r L o a d m m

(in .)

N

(lb ) m in

3 . 3 ( 0 . 1 3 )

0 . 7 – 1 . 6 ( 0 . 1 6 – 0 . 3 6 )

4 5 . 3 ( 1 . 7 8 ) *

3 7 . 0 ( 1 . 4 6 )

4 8 2 3 – 5 3 7 9 ( 1 0 8 4 – 1 2 0 9 ) * *

1 6 . 0 0 ( 0 . 6 3 0 ) *

4 5 . 2 ( 1 . 7 8 ) * *

2 7 . 5 ( 1 . 0 8 )

5 7 6 3 – 6 3 6 9 ( 1 2 9 6 – 1 4 3 2 ) * *

1 . 7 0 ( 0 . 0 6 7 ) *

1 2 . 0 0 ( 0 . 4 7 2 ) *

3 8 . 9 * * ( 1 . 5 3 )

2 4 . 5 ( 0 . 9 6 )

2 3 2 – 2 5 6 * * ( 5 2 . 2 – 5 7 . 6 )

1 1 *

1 . 7 0 ( 0 . 0 6 7 ) *

1 2 . 0 0 ( 0 . 4 7 2 ) *

3 8 . 9 ( 1 . 5 3 ) * *

2 4 . 5 ( 0 . 9 6 )

2 3 2 – 2 5 6 ( 5 2 . 2 – 5 7 . 6 ) * *

3 9 . 2 ( 1 . 5 4 ) *

2 5 . 0 ( 0 . 9 8 )

3 0 4 4 – 3 3 6 4 ( 6 8 4 – 7 5 6 ) * *

1 1 4 .3 ( 4 .5 0 )

9 1 .1 ( 3 . 5 9 )

2 0 0 . 0 – 2 2 6 . 6 ( 4 4 . 9 6 – 5 0 . 9 4 )

F o l d o u t 1 1 A F o l d o u t 1 1 B

2 3 /2 3

C 5 R e t a in e r

2 9 5 0 7 7 8 0

N o C o d e

9 . 5 *

1 . 8 3 ( 0 . 0 7 2 ) *

1 4 . 3 5 ( 0 . 5 6 5 ) *

F o l d o u t 1 1 A F o l d o u t 1 1 B

4 6 / 5 5

R e ta rd e r

2 9 5 1 5 6 9 2

N o n e

1 1 .4

4 .1 2 ( 0 .1 6 2 )

3 6 .1 7 ( 1 .4 2 )

F o l d o u t 1 1 B F o l d o u t 1 7 - 2

2 3 / 1 6

C 5 R e t a in e r

2 9 5 0 0 8 6 7

N o C o d e

1 1 . 5 *

2 . 1 6 ( 0 . 0 8 5 ) *

1 6 . 0 0 ( 0 . 6 3 0 ) *

5 2 . 1 ( 2 . 0 5 ) * *

3 3 . 00 ( 1 . 3 0 )

3 0 3 4 – 3 4 9 8 ( 6 8 2 . 1 – 7 8 6 . 4 ) * *

F o l d o u t 1 4 4

1 3

C 6 S p r in g R e t a i n e r A s s e m b l y

2 9 5 0 1 1 9 1

N o C o d e

1 0

1 .8 4 ( 0 .0 7 2 )

1 2 . 7 0 ( 0 . 5 0 0 )

3 5 . 1 0 ( 1 . 3 8 2 )

2 6 . 2 0 ( 1 . 0 3 2 )

2 1 – 2 3 3 1 ( 4 7 4 – 5 2 4 ) * *

7 1

A T r im

2 3 0 4 9 3 3 8

N o C o d e

4

0 .6 7 ( 0 .0 2 6 )

1 1 . 0 5 ( 0 . 4 3 5 5 )

6 . 5 ( 0 . 2 6 )

3 . 4 5 ( 0 . 1 4 4 ) )

3 . 2 – 4 . 2 ( 0 . 7 2 – 0 . 9 4 )

F o ld o u t 1 5 - 1

†

F o ld o u t 1 5 - 1

6 6

L o c k U p

2 9 5 4 2 9 3 8

N o C o d e

F o ld o u t 1 5 - 1

8 9

D

T r im

2 9 5 4 2 9 3 6

N o C o d e

F o l d o u t 1 5 - 1

7 6

T r im

2 9 5 4 2 9 3 6

F o l d o u t 1 5 - 1 F o l d o u t 1 5 - 1

7 9 8 3

2 9 5 4 2 9 4 1

B

D i a g n o s tic T r im C

2 9 5 4 2 9 3 6

4

0 .6 7 (0 .0 2 6 )

1 1 .0 5 ( 0 . 4 3 5 ) ) †

6 . 5 ( 0 0 . 2 6 )

3 .4 5 ( 0 . 1 4 )

0 . 7 2 – 0 . 9 4 ( 0 . 7 2 – 0 . 9 4 )

4

0 .6 7 ( 0 .0 2 6 )

1 1 . 0 5 ( 0 . 4 3 5 ) †

6 . 5 ( 0 . 2 6 )

3 . 4 5 ( 0 . 1 4 )

3 . 2 – 4 . 2 ( 0 . 7 2 – 0 . 9 4 )

N o C o d e

4

0 . 6 7 7 ( 0 . 0 2 6 )

1 1 . 0 5 ( 0 . 4 3 5 ) †

6 . 5 ( 0 . 2 6 )

3 . 4 5 5 ( 0 . 1 4 )

3 . 2 – 4 . 2 ( 0 . 7 2 – 0 . 9 4 )

N o C o d e N o C o d e

9

1 .3 0 ( 0 .0 3 9 )

1 0 . 5 0 ( 0 . 4 3 3 )

2 7 . 0 3 ( 1 . 0 6 )

1 5 . 4 9 ( 1 . 0 2 ) )

2 .4 5

( 0 . 7 8 )


T a b le F o l d o u t


R e f.

S p r in g

C o l o r N o . C o i l s C o d e

D a t a ( c o n t ’ d ) W i r e D i a . m m ( i n . )

A p p r o x . S p r i n g O D F r e e L e n g t h m m ( i n . ) m m ( i n . )

L e n g t h U n d e r L o a d m m

(in .)

N

(lb ) m in

F o ld o u t 1 5 - 1

1 0 0

L o c k u p R e l a y

2 3 0 4 9 3 2 6

N o C o d e

1 0

1 .3 7 ( 0 .0 5 4 )

1 4 . 1 0 ( 0 . 5 5 5 )

4 2 . 1 ( 1 . 6 6 )

1 7 . 0 ( 0 . 6 7 )

4 9 . 2 – 6 0 . 2 ( 1 1 . 0 6 – 1 3 . 5 3 )

F o ld o u t 1 5 - 1

1 0 4

L u b e R e g u l a t o r

2 3 0 4 9 3 2 7

R e d

1 3

1 .2 2 ( 0 .0 4 8 )

1 1 . 1 0 ( 0 . 4 3 7 )

4 6 . 3 ( 1 . 8 2 )

2 3 . 5 ( 0 . 9 3 )

4 6 . 5 – 5 1 . 3 ( 1 0 . 5 – 1 1 . 5 )

F o ld o u t 1 5 - 1

1 0 8

M a in R e g u l a t o r

2 9 5 0 0 9 6 3

L t. B lu e

1 5

2 .8 7 ( 0 .1 1 3 )

2 2 . 0 ( 0 .8 6 6 )

9 8 . 5 ( 3 .8 8 )

5 4 . 6 ( 2 . 1 5 )

3 0 5 – 3 3 7 ( 6 8 . 6 – 7 5 . 8 )

F o ld o u t 1 5 - 1

1 1 2

C o n tr o l M a in

2 9 5 4 2 9 2 6

O ra n g e

1 0

1 .8 3 ( 0 .0 7 2 )

1 4 .8 ( 0 .5 8 3 )

4 4 .6 (1 .7 6 )

2 4 .2 ( 0 . 9 5 )

1 3 1 – 1 4 5 ( 2 9 . 5 – 3 2 . 6 )

F o ld o u t 1 5 - 1

1 2 3

C 2 L a t c h

2 9 5 4 2 9 2 9

L t . G r e e n

1 1

1 .3 2 ( 0 .0 5 2 )

1 1 . 4 3 ( 0 . 4 5 0 )

4 1 . 3 ( 1 . 6 3 )

1 9 . 0 ( 0 . 7 5 )

6 4 . 1 – 7 8 . 3 ( 1 4 . 4 – 1 7 . 6 )

F o l d o u t 1 5 - 1

1 2 7 E x h a u s t B a c k

2 3 0 4 9 3 9 1

N o C o d e

1 7

0 .6 1 ( 0 .0 2 4 )

7 .8 0 ( 0 .3 0 7 )

2 9 . 2 ( 1 .1 5 )

1 8 . 2 ( 0 . 7 2 )

2 . 4 0 – 2 . 9 4 ( 0 . 5 4 – 0 . 6 6 )

F o l d o u t 1 5 - 1

1 3 0 C 1 L a t c h

2 9 5 4 2 9 2 9

B lu e

1 2

1 .3 7 ( 0 .0 5 4 )

1 6 . 2 6 ( 0 . 6 4 0 )

4 6 . 2 ( 1 . 8 2 )

2 9 . 2 ( 1 . 1 5 )

1 6 . 7 – 1 8 . 9 ( 3 . 7 5 – 4 . 2 5 )

F o l d o u t 1 5 - 1

1 3 4 C o n v e r t e r R e g u l a t o r

2 9 5 0 7 4 5 6

P in k

1 0 .2

1 .5 7 (0 .0 6 0 )

1 1 .0 0 ( 0 . 4 3 3 )

3 0 .3 (1 .1 9 )

2 2 .8 ( 0 . 9 0 )

5 3 . 7 – 5 9 . 3 ( 1 2 . 0 – 1 3 . 3 )

6 7 / 7 4 R e t a r d e r V a l v e B o d y

2 9 5 2 9 3 1 0

L t G r e e n / L t G r a y

1 0 . 4 5

0 .9 7 ( 0 .0 3 8 )

1 2 .1 9 ( 0 .5 0 )

3 8 . 1 5 ( 1 .5 0 )

1 7 . 7 0 ( 0 . 7 0 )

1 4 . 7 0 ( 1 0 . 8 4 )

2 6 M a in P r e s s u r e R e l i e f V a l v e

2 9 5 0 7 7 0 9

N o C o d e

1 0 . 0

3 .2 5 ( 0 .1 2 8 )

1 7 .9 6 ( 0 .7 1 )

5 2 . 3 8 ( 2 .0 6 )

4 0 . 6 6 ( 1 . 6 1 )

5 0 9 . 3 0 ( 3 7 5 . 5 9 )

2 9 5 4 6 5 4 9

L t B lu e

1 0 .7 7

1 .0 9 ( 0 .0 4 3 )

1 0 .8 0 ( 0 .4 3 )

2 7 . 3 0 ( 1 .0 7 )

1 6 . 6 7 ( 0 . 6 6 )

1 8 . 6 9 ( 1 3 . 7 8 )

F o l d o u t 1 1 A F o l d o u t 7 - 1

F o ld o u t 1 5 - 1 *

1 6 1

F i l t e r L i f e

I n d i v i d u a l S p r i n g s F o r t h e C o m p le t e S p r i n g A s s e m b l y † O D a t L a r g e r E n d * *

7 7-

P a r t N o .

7 -2 . S p r in g

W E A R L IM IT S A N D S P R NI G D A TA

7 8-



S E C T IO N 8 – 1 . T A A d

h e llis llis e a

O W

s a o n o n le r s

N E R

8 —

C U S T O M E R

A S S IS T A N C E

S b a A y m

t is f a c t i o n a n d g o o d w ill o f t h e o w n e r s o f t r a n s m i s s i o n s a r e o f p r i m a r y c o n c e r n t o T r a n s m i s s i o n , i t s d i s t r i b u t o r s , a n d t h e i r .

A s a n o w n e r o f a n A l l i s o n t r a n s m i s s i o n , y o u h a v e s e r v i c e l o c a t i o n s t h r o u g h o u t t h e w o r l d t h a t a r e e a g e r t o m e e t y o u r p a r t s a n d s e r v ic e n e e d s w it h :

t e p T w o — W h e n i t a p p e a r s t h e e r e a d ily r e s o lv e d a t t h e d is t r ib u d d i t io n a l a s s is t a n c e , c o n ta c t t h e s s is ta n c e C e n t e r a t 8 0 0 - 2 5 2 - 5 2 o u in c o n t a c t w ith t h e r e g io n a l c a n a g e r f o r y o u r a r e a .

• T a e T n

• S a le s t e a m s t o h e lp d e t e r m in e y o u r t r a n s m i s s i o n r e q u i r e m e n t s • P r o d u c t i n f o r m a t i o n a n d l i t e r a t u r e . a l l y , a n y s i t u a t i o n t h a t a r i s e s i n c o n n e c t i o n w i t h a l e , o p e r a t i o n , o r s e r v i c e o f y o u r t r a n s m i s s i o n e h a n d l e d b y t h e d i s t r i b u t o r o r d e a l e r i n a r e a . C h e c k t h e t e l e p h o n e d i r e c t o r y f o r t h e n T r a n s m i s s i o n s e r v i c e o u t l e t n e a r e s t y o u e A l l is o n T r a n s m is s io n ’s S a l e s a n d S e r v ic e t o r t o o l o n t h e A l l is o n T r a n s m is s io n w e b s it e a t . a l l i s o n t r a n s m i s s i o n . c o m . Y o u m a y a l s o r e f e r t o n T r a n s m i s s i o n ’ s W o r l d w i d e S a l e s a n d S e r v i c e t o r y ( S A 2 2 2 9 E N ) . t d e s p i t e t h e c o n c e r n e d , u r. T o fu r th e r a s s e h a v e d e v e lo p e r e to b e fo llo w e d n h a n d le d s a t is fa

u r e d t h e i n t h e c t o r ily .

S t e p O n e — D i s c u s s y o u r p r o b l e m w i t h a m e m b e r o f m a n a g e m e n t f r o m t h e d i s t r ib u t o r o r d e a l e r s h i p . F r e q u e n t l y , c o m p l a i n t s a r e t h e r e s u l t o f a b r e a k d o w n in c o m m u n i c a t io n a n d c a n b e r e s o lv e d q u i c k ly b y a m e m b e r o f m a n a g e m e n t. I f y o u h a v e a lr e a d y d i s c u s s e d t h e p r o b l e m w i t h t h e s a l e s o r s e r v ic e m a n a g e r , c o n t a c t t h e g e n e r a l m a n a g e r . A l l A l l i s o n T r a n s m i s s i o n d e a l e r s a r e a s s o c i a t e d w i t h a n A l l i s o n T r a n s m i s s i o n d i s t r i b u t o r . I f t h e p r o b l e m o r i g i n a t e s w it h a d e a l e r , e x p l a i n t h e m a t t e r t o a m a n a g e m e n t m e m b e r o f t h e d i s t r ib u t o r w it h w h o m t h e d e a le r h a s h i s s e r v i c e a g r e e m e n t . T h e d e a l e r w i l l p r o v i d e h i s A l l i s o n T r a n s m i s s i o n d i s t r i b u t o r ’ s n a m e , a d d r e s s , a n d t e le p h o n e n u m b e r o n r e q u e s t. C o p y r ig h t ©

2 0 0 9

c a n n o t w i t h o u t e c h n i c a l w i l l p l a c e s u p p o r t

• T y p e a n d m a k e o f v e h ic le / e q u i p m e n t

• C o m p l e t e p a r t s s u p p o r t

e v e r, th a v e ry o n e m a y o c c fa c t io n , w p r o c e d u s n o t b e e

le m v e l o n T h e y e r

• N a m e a n d l o c a t i o n o f t h e a u t h o r i z e d d i s t r i b u t o r o r d e a l e r

• E m e r g e n c y s e r v ic e 2 4 h o u r s a d a y in m a n y a r e a s

W e re c o g n iz e , h o w b e s t in t e n t io n s o f e m is u n d e r s ta n d in g s y o u r c o m p le t e s a t is f o l lo w in g th r e e - s t e p e v e n t a p r o b le m h a

p ro b to r le A llis 8 3 . T u s to m

F o r p r o m p t a s s i s t a n c e , p l e a s e h a v e t h e f o l lo w in g i n f o r m a t i o n a v a i l a b l e .

• E x p e r t s e r v ic e b y t r a i n e d p e r s o n n e l

N o rm th e s w ill b y o u r A l l i s o o r u s L o c a w w w A l l i s o D ir e c

S E R V IC E

ra n n d le c ra n u m

s m a s tro s m b e

is s s e m n ic is s r )

io n b ly c o n io n

m o d e l n u n u m b e r t r o l s , a ls C o n tro l M

m b ( if o p o d

e r, e q u ro v u le

s e r ip p id e [T C

ia l n u m b e r , e d w it h t h e M ] a s s e m b l y

• T r a n s m i s s io n d e l i v e r y d a t e a n d a c c u m u l a t e d m i l e s a n d / o r h o u r s o f o p e r a t i o n • N a t u r e o f p r o b l e m • C h r o n o l o g ic a l s u m m a r y o f y o u r t r a n s m is s io n ’s h i s t o r y S c p w

te p o n ta re s e r it in

T h r e e — I f y c t in g t h e r e g n t t h e e n t ir e g to t h e fo llo

A M P In

llis o n T r a n a n a g e r, W .O . B o x 8 9 d ia n a p o lis

s m is s a rra n 4 , M a , IN 4

o u io m w

a re n a l c a tte in g a

s till u s to r to d d re

n o t s a t i s fi e d a f t e r m e r s u p p o r t m a n a g e r , t h e h o m e o f fi c e b y s s :

i o n t y A d m i n i s t r a t i o n il C o d e A 0 1 6 2 0 6 - 0 8 9 4

I n c l u d i n g a l l p e r t i n e n t i n f o r m a t i o n w i l l a s s i s t t h e h o m e o f fi c e in e x p e d i t in g t h e m a t t e r . W in re fa it e x

h e n c o n ta c tin g t h e h o m m in d th a t u l tim a t e l y t h e s o lv e d a t th e d i s t r ib u t o r c ilitie s , e q u i p m e n t , a n d is s u g g e s te d t h a t S te p p e r ie n c i n g a p r o b le m .

e o ffi p r o b o r d e p e rs o 1 b e

c e , p l e a s e k e e p l e m w i l l l i k e l y b e a l e r s h i p u s i n g t h e i r n n e l . T h e r e f o r e , f o l lo w e d w h e n

Y o u r p u r c h a s e o f a n A l l is o n T r a n s m is s io n p r o d u c t i s g r e a t l y a p p r e c i a t e d , a n d i t i s o u r s i n c e r e d e s i r e t o a s s u r e c o m p l e t e s a t i s f a c t i o n .


8 - 1

S E R V IC E

8 – 2 .

S E R V IC E

A d d i t i o n a l s e lite r a tu r e p r o o p e r a t io n , m p a rts s u p p o r th a t y o u g e t fro m y o u r tra f r o m :


L IT E R A T U R E

r v ic e lit e r a t u r e is a v a v i d e s f u lly illu s t r a t e d a in t e n a n c e , s e r v ic e , t f o r y o u r t r a n s m is s io m a x im u m p e r f o r m a n n s m is s io n , y o u m a y

P u b lic a tio n

i l a b l e . T h i s s e r v i c e i n s t r u c t i o n s f o r o v e r h a u l , a n d n . T o m a k e s u r e c e a n d s e r v ic e lif e o r d e r p u b l i c a t i o n s

T S 3 9 8 9 E N

*

S A 2 2 2 9 E N

W o r ld w id e S a le s a n d D i r e c t o r y *

A l l i s o n D O C ® F o r P C U s e r G u id e

3 0 0 0 P r o d u c t F a m i l y

– S e r v ic e T o o l

G N 3 4 3 3 E N

*

M T 4 0 1 5 E N M T 4 1 0 8 E N

*

M e c h a n i c ’s T i p s ( E m e r g e n c y V e h ic l e S e r i e s )

M T 3 6 5 7 E N

*

M e c h a n ic ’s T i p s ( T r u c k R e c r e a t i o n a l V e h i c l e S e r i e s )

M T 3 6 5 5 E N

*

M T 4 0 8 5 E N

*

O M 3 7 4 9 E N

*

O p e r a t o r ’s M a n u a l ( E m e r g e n c y V e h i c l e S e r i e s )

O M 3 6 5 6 E N

*

O M 3 7 5 0 E N

*

O p e r a t o r ’s M a n u a l ( M o t o r h o m e S e r i e s )

O M 3 3 4 9 E N

*

O p e r a t o r ’s M a n u a l ( P u p i l T r a n s p o r t / S h u t t l e S e r i e s )

O M 3 7 5 1 E N

*

O p e r a t o r ’s M a n u a l ( R u g g e d D u t y S e r i e s )

O M 3 7 5 2 E N

*

O M 3 7 5 3 E N

*

O p e r a t o r ’s M a n u a l ( T S e r ie s )

O M 3 5 2 9 E N

P a r ts C a ta lo g

P C 2 1 5 0 E N

P a r ts C a ta lo g o n C D - R O M

C D 2 1 5 0 E N

P r in c ip le s o f O p e r a tio n

P O 4 0 1 6 E N

*

S M 4 0 1 3 E N

M e c h a n ic ’s T ip s

M e c h a n i c ’s T i p s ( T S e r ie s ) O p e r a t o r ’s M a n u a l ( B u s S e r ie s )

O p e r a to r ’s M a n u a l ( H ig h w a y S e r ie s )

O p e r a t o r ’ s M a n u a l ( S p e c ia l t y S e r i e s )

S e r v ic e M a n u a l

8 - 2

C o p y r ig h t ©

S e r v ic e

A l s o A v a i l a b l e O n T h e I n t e r n e t A t w w w . a l l i s o n t r a n s m i s s i o n . c o m

T a b l e 8 – 1 . S e r v i c e L i t e r a t u r e N a m e

3 0 0 0 P r o d u c t F a m i l y

T r o u b le s h o o t in g M a n u a l

S G I , I n c . A t t n : A l l i s o n L i t e r a t u r e F u l fi l l m e n t D e s k 8 3 5 0 A llis o n A v e n u e I n d i a n a p o l i s , I N 4 6 2 6 8 T O L L F R E E : 8 8 8 – 6 6 6 – 5 7 9 9 I N T E R N A T I O N A L : 3 1 7 – 4 7 1 – 4 9 9 5

P u b lic a tio n

N a m e


S E R V IC E


L e g e n d

fo r F o ld o u t 1 Is O n

C o p y r ig h t ©

2 0 0 9

T h e O p p o s i t e S i d e O f T h is P a g e .


F o ld o u t 1

S E R V IC E


L e g e n d (1 )

–

L o c k u p c l u t c h a n d d a m p e r a s s e m b ly

(2 ) (3 )

– –

C o n v e r t e r t u r b in e C o n v e r te r p u m p

(4 )

–

C o n v e r te r h o u s in g

(5 ) (6 )

– –

F r o n t s u p p o r t R o t a t i n g c lu t c h m o d u le

(7 ) (8 )

– –

C 2 c lu t c h M a in c a s e m o d u le

(9 )

–

C 3 c lu t c h

(1 0 ) (1 1 )

–

P 1 p la n e t a r y m o d u le C 4 c lu tc h

(1 2 )

–

P 2 p la n e t a r y m o d u le

(1 3 )

–

C 5 c lu tc h

(1 4 )

–


(1 5 ) (1 6 )

– –

R e a r c o v e r m o d u le O u t p u t s h a ft

(1 7 )

–

M a in s h a f t m o d u le

(1 8 ) (1 9 )

– –

O il le v e l s e n s o r C o n t r o l v a lv e m o d u le

(2 0 )

–

C 1 c lu tc h

(2 1 ) (2 2 )

– –

O il p u m p G r o u n d s le e v e

(2 3 )

–

C o n v e r t e r s ta t o r

(2 4 )

–

T u r b in e s h a ft

–

F o l d o u t 1

C o p y r ig h t ©

f o r F o l d o u t 1


F O L D O U T 1

F o l d o u t 1 . 3 0 0 0 P r o d u c t F a m ily

T r a n s m is s io n —

C r o s s

S e c t i o n

S E R V IC E


L e g e n d


C o p y r ig h t ©

2 0 0 9



F o ld o u t 2

S E R V IC E


L e g e n d (1 )

–


(2 ) (3 )

– –


(4 )

–


(5 ) (6 )

– –

P T O g e a r a s s e m b ly F r o n t s u p p o r t

(7 ) (8 )

– –

R o t a t i n g c lu t c h m o d u le C 2 c lu t c h

(9 )

–

M a in c a s e m o d u le

(1 0 ) (1 1 )

–

C 3 c lu tc h P 1 p la n e t a r y m o d u le

(1 2 )

–

C 4 c lu tc h

(1 3 )

–


(1 4 )

–

C 5 c lu tc h

(1 5 ) (1 6 )

– –

P 3 p la n e t a r y m o d u le R e t a r d e r h o u s in g

(1 7 )

–

S t a t o r a s s e m b ly

(1 8 ) (1 9 )

– –

R o t o r a s s e m b ly O u tp u t s p e e d s e n s o r

(2 0 )

–

R e m o t e m a n if o ld

(2 1 ) (2 2 )

– –

O u t p u t s h a ft M a in s h a f t m o d u le

(2 3 )

–

O il le v e l s e n s o r

(2 4 )

–

C o n t r o l v a lv e m o d u le

(2 5 ) (2 6 )

– –

C 1 c lu tc h O il p u m p

(2 7 )

–

I n p u t s p e e d s e n s o r

(2 8 )

–

G r o u n d s le e v e

(2 9 ) (3 0 )

– –

C o n v e r t e r s ta t o r T u r b in e s h a ft

–

F o l d o u t 2

C o p y r ig h t ©



F O L D O U T 2

F o ld o u t 2 . 3 0 0 0 P r o d u c t F a m ily

T r a n s m is s io n

(E x c e p t 3 7 0 0 S P ) w ith

P T O

P r o v is io n

a n d

R e t a rd e r—


S E R V IC E


L e g e n d


C o p y r ig h t ©

2 0 0 9



F o ld o u t 3

S E R V IC E


L e g e n d (1 )

–


(2 ) (3 )

– –


(4 )

–


(5 ) (6 )

– –

F r o n t s u p p o r t R o t a t i n g c lu t c h m o d u le

(7 ) (8 )

– –

C 2 c lu t c h M a in c a s e m o d u le

(9 )

–

C 3 c lu t c h

(1 0 ) (1 1 )

–

P 1 p la n e t a r y m o d u le C 4 c lu tc h

(1 2 )

–


(1 3 )

–

C 5 c lu tc h

(1 4 )

–


(1 5 ) (1 6 )

– –

R e a r c o v e r m o d u le O u t p u t s h a ft

(1 7 )

–

M a in s h a f t m o d u le

(1 8 ) (1 9 )

– –

O il le v e l s e n s o r C o n t r o l v a lv e m o d u le

(2 0 )

–

C 1 c lu tc h

(2 1 ) (2 2 )

– –

O il p u m p G r o u n d s le e v e

(2 3 )

–


(2 4 )

–


–

F o l d o u t 3

C o p y r ig h t ©



F O L D O U T 3

F o ld o u t 3 . 3 5 0 0

T r a n s m is s io n —

C r o s s

S e c t i o n

S E R V IC E


L e g e n d


C o p y r ig h t ©

2 0 0 9



F o ld o u t 4

S E R V IC E


L e g e n d (1 )

–


(2 ) (3 )

– –


(4 )

–


(5 ) (6 )

– –

P T O g e a r a s s e m b ly F r o n t s u p p o r t

(7 ) (8 )

– –

R o t a t i n g c lu t c h m o d u le C 2 c lu t c h

(9 )

–

M a in h o u s i n g m o d u le

(1 0 ) (1 1 )

–

C 3 c lu tc h P 1 p la n e t a r y m o d u le

(1 2 )

–

C 4 c lu tc h

(1 3 )

–


(1 4 )

–

C 5 c lu tc h

(1 5 ) (1 6 )

– –

P 3 p la n e t a r y m o d u le T r a n s fe r c a s e a d a p t e r h o u s i n g

(1 7 )

–

T r a n s f e r c a s e m o d u le

(1 8 ) (1 9 )

– –

C 6 c lu tc h T r a n s f e r c a s e r e a r o u t p u t s h a f t

(2 0 )

–

C 7 c lu tc h

(2 1 ) (2 2 )

– –

T r a n s f e r c a s e f r o n t o u t p u t s h a f t M a in s h a f t m o d u le

(2 3 )

–


(2 4 )

–

C 1 c lu tc h

(2 5 ) (2 6 )

– –

O il p u m p O il p u m p d r iv e h u b

(2 7 )

–

G r o u n d s le e v e

(2 8 )

–


(2 9 )

–


–

F o l d o u t 4

C o p y r ig h t ©



F O L D O U T 4

F o ld o u t 4 . 3 7 0 0 S P

T r a n s m i s s io n —


S E R V IC E


L e g e n d


C o p y r ig h t ©

2 0 0 9



F o ld o u t 5


S E R V IC E

L e g e n d (1 )

–

C o n v e r t e r e n d p lu g , t h r e a d e d

(2 ) (3 )

– –

O - r in g T o r q u e c o n v e r t e r m o d u le

(4 )

–

N u t , M 8 ( 3 6 ) , A

(5 ) (6 )

– –

T o r q u e c o n v e r t e r c o v e r a s s e m b ly C o v e r a n d b u s h in g a s s e m b ly

(7 ) (8 )

– –

T o r q u e c o n v e r t e r c o v e r B u s h in g

(9 )

–

L o c k u p p is to n s e a lr in g

(1 0 ) (1 1 )

–

L o c k u p p is to n a s s e m b ly L o c k u p p is to n s e a lr in g

(1 2 )

–

L o c k u p c lu t c h a n d d a m p e r a s s e m b ly

(1 3 )

–

L o c k u p c lu t c h b a c k p la t e

(1 4 )

–

B o l t , M 8 x 1 . 2 5 x 3 0 A

(1 5 ) (1 6 )

– –

H o o k - t y p e s e a lr in g T h r u s t b e a r in g a s s e m b ly

(1 7 )

–

T o r q u e c o n v e r t e r t u r b in e a s s e m b ly

(1 8 ) (1 9 )

– –

S t a t o r t h r u s t b e a r in g a s s e m b ly S t a r w a s h e r

(2 0 )

–

T o r q u e c o n v e r t e r s ta t o r a s s e m b ly

(2 1 ) (2 2 )

– –

R e t a in in g r in g S t a t o r t h r u s t p l a t e a s s e m b l y

(2 3 )

–

S t a t o r t h r u s t w a s h e r

(2 4 )

–

T o r q u e c o n v e r t e r s t a t o r r a c e

(2 5 ) (2 6 )

– –

T o r q u e c o n v e r t e r s t a t o r s p r i n g ( 1 3 ) T o r q u e c o n v e r t e r s t a t o r r o l l e r ( 1 3 )

(2 7 )

–

S t a to r a n d c a m

(2 8 )

–

S h im , c o n v e r t e r, 0 .2 5 4 0 m m s e l e c t i v e

( 0 . 0 1 0 in c h ) ,

(2 8 )

–

S h im , c o n v e r t e r, 0 .4 8 2 6 m m s e l e c t i v e

( 0 . 0 1 9 in c h ) ,

(2 8 )

–

(2 9 )

–

S h im , c o n v e r t e r , 0 . 7 1 1 2 m m ( 0 . 0 2 8 in c h ) , s e l e c t i v e P u m p t h r u s t b e a r in g a s s e m b ly

(3 0 )

–

O - r in g

(3 1 )

–

T o r q u e c o n v e r t e r p u m p a s s e m b ly

(3 2 ) (3 3 )

– –

P u m p t h ru s t w a s h e r T o r q u e c o n v e r t e r p u m p a s s e m b ly

(3 4 )

–

T - h e a d b o lt ( 3 6 )

–

T o rq u e A

F o l d o u t 5


a s s e m b ly

N ∙m 3 0 – 3 5

lb

f t

2 2 – 2 6

C o p y r ig h t ©


F O L D O U T 5

F o ld o u t 5 . T o r q u e C o n v e rte r M o d u le —

D i s a s s e m b le d

V i e w

S E R V IC E


L e g e n d


C o p y r ig h t ©

2 0 0 9



F o ld o u t 6


S E R V IC E

L e g e n d


6 - 1

6 - 2

(1 )

–

T o r q u e c o n v e r t e r h o u s i n g m o d u le

(1 )

–

(2 ) (3 )

– –

T o r q u e c o n v e r t e r h o u s in g S p e e d s e n s o r a s s e m b ly

(2 ) (3 )

– –

(4 )

–

O - r in g

(4 )

–

O i l s e a l a s s e m b ly

(5 )

–

S p e e d s e n s o r r e t a in e r

(5 )

–

B e a r in g r e t a in e r a s s e m b ly

(6 ) (7 )

– –

B o l t , M 8 x 1 . 2 5 x 2 0 , A T o r q u e c o n v e r t e r h o u s in g g a s k e t

(6 ) (7 )

– –

B e a r i n g r e t a i n e r b u s h in g B e a r in g r e t a in e r

(8 ) (9 )

– –

B o l t , M 1 0 x 1 . 5 x 3 5 ( 2 0 ) , B V e n t a s s e m b l y , M 1 0 x 1 . 5 , C

(8 ) (9 )

– –

S e a lr i n g P T O g e a r a s s e m b ly

S e n s o r s h ip p in g c o v e r

(1 0 )

P r e s s u r e t a p p l u g a s s e m b l y , D

(1 1 )

(1 0 ) (1 1 )

– –

C o n v e r t e r h o u s in g m o d u le B o l t , M 1 0 x 1 . 5 x 3 5 ( 1 0 ) , A B e a r in g r e t a in e r a s s e m b ly

– –

S e a lr in g S in g le r o w

b a ll b e a r in g

(1 2 )

–

O - r in g

(1 2 )

–

P T O

(1 3 )

–

P r e s s u r e t a p p lu g

(1 3 ) (1 4 )

– –

O il p u m p d r iv e h u b S in g le r o w b a ll b e a r in g

ft

(1 5 )

–

I n t e r n a l r e t a i n i n g r i n g

T o rq u e

N ∙m

lb

g e a r

A

2 4 – 2 9

1 8 – 2 1

(1 6 ) (1 7 )

– –

S e a lr in g C o n v e r t e r h o u s i n g a s s e m b ly

B

5 1 – 6 1

3 8 – 4 5

(1 8 )

–

S p e e d s e n s o r a s s e m b ly

C

1 2 – 1 6

9 – 1 2

(1 9 )

–

O - r in g

D

1 0 – 1 3

7 – 1 0

(2 0 )

–


(2 1 ) (2 2 )

– –

B o l t , M 8 x 1 . 2 5 x 2 0 , B C o n v e r t e r h o u s in g

(2 3 )

–

S e n s o r s h ip p in g c o v e r

(2 4 ) (2 5 )

– –

P T O P T O

(2 6 )

–

B o l t , M 1 0 x 1 . 5 x 2 5 ( 2 0 ) , A

(2 7 )

–

B o l t , M 1 0 x 1 . 5 x 3 5 ( 2 0 ) , A

(2 8 )

–

V e n t a s s e m b l y , M 1 0 x 1 . 5 , C

(2 9 ) (3 0 )

– –

B r e a t h e r a d a p t e r , M 1 0 x 1 . 5 , C T o r q u e c o n v e r t e r h o u s in g g a s k e t

c o v e r g a s k e t ( 2 ) c o v e r ( 2 )

T o rq u e

F o l d o u t 6

C o p y r ig h t ©

N ∙m

lb

ft

A

5 1 – 6 1

3 8 – 4 5

B

2 4 – 2 9

1 8 – 2 1

C

1 2 – 1 6

9 – 1 2


F O L D O U T 6

F o ld o u t 6 -1 . C o n v e r t e r H o u s in g M o d u l e , W i t h o u t P T O

P r o v i s io n — D i s a s s e m b l e d V i e w

F o ld o u t 6 - 2 . C o n v e r t e r H o u s in g M o d u l e , W i t h P T O

P r o v i s io n — D i s a s s e m b l e d V ie w

S E R V IC E


L e g e n d


C o p y r ig h t ©

2 0 0 9



F o ld o u t 7


S E R V IC E

L e g e n d


7 - 1 (1 )

–

B o l t , M 1 0 x 1 . 5 x 6 0 ( 6 ) , A B o l t , M 1 0 x 1 . 5 x 3 5 ( 5 ) , A

(2 ) (3 )

– –

(4 )

–

O - r in g ( w it h o u t P T O

(5 )

–

O il s e a l a s s e m b ly ( w ith o u t P T O

(6 ) (7 )

– –

B o lt , M 1 0 x 1 . 5 x 6 0 ( 8 ) , A P u m p h o u s in g a s s e m b ly

(8 ) (9 )

– –

B u s h in g ( w it h o u t P T O P u m p h o u s in g

F r o n t s u p p o r t m o d u le

(1 0 )

–

(1 1 )

–

o n ly ) o n ly )

o n ly )

S h im , t o r q u e c o n v e r te r t u r b in e , 4 . 0 0 0 m m i n c h ) , s e l e c t iv e

(3 )

–

R o t a t i n g c lu t c h m o d u le

(4 )

–

O - r in g

(5 )

–

T u r b in e s h a f t a s s e m b ly ( w it h o u t P T O )

(6 ) (7 )

– –

T u r b in e s h a f t T u r b in e s h a f t b u s h in g

(8 ) (9 )

– –

T u r b in e s h a ft a s s e m b ly ( w it h P T O ) T u r b in e s h a f t

(1 1 )

B u s h in g

(1 2 )

–

B o l t , M 1 0 x 1 . 5 x 2 5 ( 1 0 ) , A

(1 3 ) (1 4 )

– –

S t if f e n in g p l a t e W e a r p la te

(1 5 )

–

F r o n t s u p p o r t a s s e m b ly

(1 6 ) (1 7 )

– –

G r o u n d s le e v e ( w ith P T O ) G r o u n d s le e v e ( w it h o u t P T O )

(1 8 )

–

F r o n t s u p p o r t a s s e m b ly

(1 9 )

–

D o w e l p in , 1 0 x 3 2 ( 2 )

(2 0 )

–

F r o n t s u p p o r t s le e v e

(2 1 ) (2 2 )

– –

F r o n t s u p p o r t R o lle r b e a r in g a s s e m b ly

(2 3 )

–

S e a lr in g ( 3 )

(2 4 ) (2 5 )

– –

T h r u s t b e a r in g a s s e m b ly D o w e l p in , 6 x 3 5

(2 6 )

–

P r e s s u r e r e l i e f s p r in g

(2 7 )

–

P r e s s u r e r e l ie f b a l l N ∙m

A

–

(1 0 )

G e a r s e t a s s e m b ly

T o rq u e

(2 )

5 1 – 6 1

lb

f t

3 8 – 4 5

7 - 2

– –

S e a lr in g ( 3 ) R o t a t in g c lu t c h d r u m

(1 2 )

–

R o t a t i n g c lu t c h h u b a s s e m b l y

(1 3 ) (1 4 )

– –

R o t a t i n g c lu t c h h u b b u s h in g R o t a t i n g c lu t c h h u b a s s e m b l y

(1 5 )

–

T h r u s t b e a r in g

(1 6 )

–

T u r b i n e s h a f t r e t a i n i n g r in g

(1 7 ) (1 8 )

– –

C 2 p i s t o n s e a lr i n g C 1 p i s t o n s e a lr i n g

(1 9 )

–

C 2 p i s t o n s e a lr i n g

(2 0 )

–

C 2 p is t o n

(2 1 ) (2 2 )

– –

C 2 s p r in g a s s e m b ly I n t e r n a l r e t a i n i n g r i n g

(2 3 )

–

C 1 p i s t o n s e a lr i n g

(2 4 )

–

C 1 p is t o n

(2 5 ) (2 6 )

– –

C 1 s p r in g a s s e m b ly R o t a t i n g c lu t c h b a l a n c e p i s t o n

(2 7 )

–

R o t a t i n g c lu t c h b a la n c e p i s t o n s e a l r i n g

(2 8 ) (2 9 )

– –

E x t e r n a l r e t a i n i n g r in g C 1 c lu t c h a p p ly p l a t e

(3 0 ) (3 1 )

– –

C 1 f r ic tio n p l a t e ( 6 ) C 1 r e a c t io n p la t e ( 5 )

(3 2 )

–

C 1 c lu t c h b a c k i n g p l a t e

(3 3 ) (3 4 )

– –

E x t e r n a l r e t a i n i n g r in g C 1 d riv e h u b

(3 5 )

–

T h r u s t b e a r in g ( 2 )

(3 6 ) (3 7 )

– –

C 2 d riv e h u b C 2 r e a c t io n p la t e ( 6 )

(3 8 ) (3 9 )

– –

C 2 f r ic tio n p l a t e ( 6 ) C 2 c lu t c h p r e s s u r e p la t e

(4 0 )

–


(1 )

–

B o l t , M 1 6 x 2 . 0 x 5 0 , A

(2 )

–

T o r q u e c o n v e r t e r t u r b in e s h im

(2 )

–

S h im , t o r q u e c o n v e r t e r t u r b in e , 5 .0 9 2 m m i n c h ) , s e l e c t i v e

( 0 . 2 0 1

(2 )

–

v e r t e r t u r b in e , 4 .9 1 4 m m

( 0 . 1 9 4

(2 )

–


( 0 . 1 8 7

(4 1 ) (4 2 )

– –

S u n g e a r a s s e m b ly S u n g e a r

(2 )

–

S in S in S in S in


( 0 . 1 8 0

(4 3 )

–

S u n g e a r b u s h in g

(4 4 )

–


(2 )

–

(2 )

–

h im c h h im c h h im c h h im c h

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rq le rq le rq le rq le

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( 0 . 1 7 3

S h im , t o r q u e c o n v e r t e r t u r b in e , 4 .2 0 3 m m i n c h ) , s e l e c t i v e

( 0 . 1 6 6

F o l d o u t 7

T o rq u e

C o p y r ig h t ©

( 0 . 1 5 8

A


N ∙m 1 0 0 – 1 2 0

lb

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F O L D O U T 7

F o ld o u t 7 -1 . F r o n t S u p p o r t a n d

O il P u m p

M o d u le —

D is a s s e m b le d

V ie w

F o ld o u t 7 -2 . R o ta tin g

C lu t c h

M o d u le —

D is a s s e m b le d

V ie w

S E R V IC E


L e g e n d


C o p y r ig h t ©

2 0 0 9



F o ld o u t 8


S E R V IC E

L e g e n d


8 - 1

8 - 2

(1 )

–

C 3 / C 4 c l u t c h a s s e m b ly

(1 )

–

S h im

( s e le c tiv e ) , 0 .2 7 m m

( 0 . 0 1 in c h )

(2 ) (3 )

– –

B o l t , M 1 0 x 1 . 5 x 9 0 ( 1 2 ) , A C 3 b a c k p la t e a s s e m b ly

(1 ) (1 )

– –

S h im S h im

( s e le c tiv e ) , 0 .5 4 m m ( s e le c tiv e ) , 0 .8 1 m m

( 0 . 0 2 in c h ) ( 0 . 0 3 in c h )

(4 )

–

C lu tc h b a c k p la te

(1 )

–

S h im

( s e le c tiv e ) , 1 .0 8 m m

( 0 . 0 4 in c h )

(5 )

–

C lu tc h w e a r p la te ( 3 )

(1 )

–

S h im

( s e le c tiv e ) , 1 .3 5 m m

( 0 . 0 5 in c h )

(6 ) (7 )

– –

P 1 r in g g e a r C 3 c lu t c h f r ic t io n p l a t e ( 5 )

(1 ) (1 )

– –

S h im S h im

( s e le c tiv e ) , 1 .6 2 m m ( s e le c tiv e ) , 1 .8 9 m m

( 0 . 0 6 in c h ) ( 0 . 0 7 in c h )

(8 ) (9 )

– –

C 3 c lu t c h r e a c t io n p la t e ( 5 ) P is to n r e t u r n p la t e

(2 ) (3 )

– –

T h r u s t b e a r in g M a in s h a f t m o d u le

C 3 c lu t c h p is to n

(4 )

–

S p i r a l r e t a i n i n g r in g

C 3 c lu t c h h o u s i n g a s s e m b ly

(5 )

–

T h r u s t b e a r in g

(1 0 ) (1 1 )

– –

(1 2 )

–

C lu t c h w e a r p la t e ( 3 )

(6 )

–

P 2 s u n g e a r

(1 3 ) (1 4 )

– –

C 3 c lu tc h h o u s in g C 4 c lu t c h r e a c t i o n p l a t e ( 6 )

(7 ) (8 )

– –

B e a r in g s p a c e r P 3 s u n g e a r

(1 5 )

–

C 4 c lu t c h f r ic t io n p l a t e ( 5 )

(9 )

–

M a in s h a f t

(1 6 ) (1 7 )

– –

P is t o n r e t u r n p l a t e C 4 c lu t c h p is to n

(1 8 )

–

C 4 c lu tc h h o u s in g

(1 9 )

–

B o l t , M 1 0 x 1 . 5 x 2 5 ( 3 ) , A

(2 0 )

–

C o n v e r t e r s h ip p i n g b r a c k e t ( 3 )

(2 1 ) (2 2 )

– –

M a in h o u s in g a s s e m b ly M a in h o u s in g

(2 3 )

–

I n s e r t , r e c o i l ( 1 2 )

(2 4 ) (2 5 )

– –

N a m e p la te S c r e w , # 4 x 1 ∕4

(2 6 )

–

S h ip p in g C o v e r

(2 7 )

–

B o l t , M 1 0 x 1 . 5 x 3 5 ( 1 2 ) , A

(2 8 )

–

C 5 c lu t c h r e a c t i o n p l a t e ( 8 )

(2 9 )

–

C 5 c lu t c h f r ic t io n p l a t e ( 7 ) T o rq u e A

F o l d o u t 8

N ∙m 5 1 – 6 1

lb

ft

3 8 – 4 5

C o p y r ig h t ©


F O L D O U T 8

F o ld o u t 8 -1 . M a in

H o u s in g M o d u le —


V ie w

F o l d o u t 8 - 2 . 3 0 0 0 P r o d u c t F a m i l y M a i n S h a f t M o d u le ( E x c e p t 3 5 0 0 a n d 3 7 0 0 S P ) —

D i s a s s e m b le d V i e w

S E R V IC E


L e g e n d


C o p y r ig h t ©

2 0 0 9



F o ld o u t 9


S E R V IC E

L e g e n d


9 - 1 A

–

3 5 0 0

(1 ) (2 )

– –

S e le c t iv e s h im T h r u s t b e a r in g a s s e m b ly

(3 )

–

M a in s h a f t m o d u l e

(4 )

–


(5 ) (6 )

– –

P 2 s u n g e a r T h r u s t b e a r in g a s s e m b ly

(7 ) (8 )

– –

B e a r in g s p a c e r M a in s h a f t

9 - 2 B

–

3 7 0 0 S P

(1 ) (2 )

– –

T h r u s t b e a r in g a s s e m b ly M a in s h a f t m o d u l e

(3 )

–


(4 ) (5 )

– –

T h r u s t b e a r in g P 2 s u n g e a r

(6 )

–

B e a r in g s p a c e r

(7 ) (8 )

– –

P 3 s u n g e a r M a in s h a f t

F o l d o u t 9

C o p y r ig h t ©


F O L D O U T 9

F o ld o u t 9 -1 . M a in S h a ft M o d u le 3 5 0 0 —


F o ld o u t 9 -2 . M a in S h a ft M o d u le 3 7 0 0 S P —


S E R V IC E


L e g e n d f o r F o ld o u t 1 0 Is O n

C o p y r ig h t ©

2 0 0 9

T h e O p p o s i t e S i d e O f T h i s P a g e .


F o ld o u t 1 0

S E R V IC E


L e g e n d

f o r F o l d o u t 1 0

1 0 - 1 (1 )

–


(2 ) (3 )

– –

I n t e r n a l r e t a i n i n g r i n g T h r u s t b e a r in g a s s e m b ly

(4 )

–

P 1 p la n e t a r y c a r r ie r a s s e m b ly

(5 )

–

R e t a in in g r in g

(6 ) (7 )

– –

P 1 in d e x in g r in g P 1 p la n e t a r y s p in d le ( 6 )

(8 ) (9 )

– –

P 1 p la n e ta r y c a r r ie r P 1 t h ru s t w a s h e r ( 6 )

(1 0 )

–

(1 1 )

–

P 1 p in io n g e a r ( 6 ) R o lle r b e a r in g a s s e m b ly ( 1 2 )

(1 2 )

–

P 1 t h r u s t w a s h e r ( 6 )

(1 3 ) (1 4 )

– –

T h r u s t b e a r in g a s s e m b ly P 2 p la n e ta r y r in g g e a r

1 0 - 2 (1 )

–


(2 )

–


(3 ) (4 )

– –

P 2 p la n e t a r y c a r r ie r a s s e m b ly C a r r ie r a n d b u s h in g a s s e m b ly

(5 )

–

P 2 p la n e ta r y c a r r ie r

(6 )

–

B u s h in g

(7 ) (8 )

– –

T h r u s t w a s h e r ( 4 ) R o lle r b e a r in g ( 8 )

(9 )

–

P 2 p in io n g e a r ( 4 )

(1 0 )

–

T h r u s t w a s h e r ( 4 )

–

P 2 p la n e t a r y s p in d le ( 4 ) P 2 in d e x in g r in g

(1 3 )

–


(1 4 )

–

P 3 p la n e ta r y r in g g e a r

(1 1 ) (1 2 )

–

F o l d o u t 1 0

C o p y r ig h t ©


F O L D O U T 1 0

F o l d o u t 1 0 - 1 . P 1 P l a n e t a r y M o d u l e — D i s a s s e m b l e d V ie w

F o l d o u t 1 0 - 2 . P 2 P l a n e t a r y M o d u l e — D i s a s s e m b l e d V ie w

S E R V IC E


L e g e n d f o r F o ld o u t 1 1 A

C o p y r ig h t ©

Is O n

2 0 0 9

T h e O p p o s it e S i d e O f T h i s P a g e .


F o l d o u t 1 1 A

S E R V IC E


L e g e n d

f o r F o l d o u t 1 1 A

(1 )

–

R e ta r d e r h o u s in g g a s k e t

(4 9 )

–

R e t a r d e r h o u s in g

(2 ) (3 )

– –

B o l t , M 1 2 x 1 . 7 5 x 1 3 0 ( 1 4 ) , A B o l t , M 1 2 x 1 . 7 5 x 1 9 0 ( 4 ) , A

(5 0 ) (5 1 )

– –

G a s k e t C o v e r

(4 )

–

B o l t , M 1 0 x 1 . 5 x 1 8 2 ( 4 ) , B

(5 2 )

–

B o l t , M 8 x 1 . 2 5 x 2 5 ( 9 ) , C

(5 ) (6 )

– –

R e t a r d e r a n d P 3 p la n e t a r y m o d u le P 3 p la n e t a r y c a r r ie r a s s e m b ly

(5 3 ) (5 4 )

– –

S p r i n g p in , 5 x 4 5 R e t a r d e r v a lv e

(7 ) (8 )

– –

O u t p u t s h a f t a s s e m b ly B u s h in g

(5 5 ) (5 6 )

– –

R e t a r d e r v a lv e s p r in g O - r in g

(9 )

–

O u tp u t s h a ft

(5 7 )

–

V a lv e p lu g

–

I n t e r n a l r e t a i n i n g r i n g P 3 in d e x in g r in g

(5 8 ) (5 9 )

– –

I n t e r n a l r e t a i n i n g r i n g O il s e a l a s s e m b ly

(1 2 )

–

P 3 p l a n e t a r y c a r r ie r

(6 0 )

–

N u t , b e a r in g r e t a in e r

(1 3 )

–

C o n e a n d r o lle r b e a r in g a s s e m b ly

(6 1 )

–

B e l le v i l le s p r i n g w a s h e r

(1 4 )

–

R e t a in in g r in g

(6 2 )

–

R o lle r b e a r in g

(1 5 ) (1 6 )

– –

P 3 p la n e t a r y s p in d le ( 4 ) P 3 t h r u s t w a s h e r ( 4 )

(6 3 ) (6 4 )

– –

S e p a r a t o r p la t e R e t a r d e r c o n t r o l b o d y a s s e m b ly

(1 7 )

–

P 3 p i n io n g e a r s e t ( s e t o f f o u r p in io n g e a r s )

(6 5 )

–

R e t a r d e r v a lv e b o d y

(1 8 ) (1 9 )

– –

R o lle r b e a r in g a s s e m b ly ( 8 ) P 3 th r u s t w a s h e r

(6 6 ) (6 7 )

– –

V a lv e S p r in g

(2 0 )

–

R e t a r d e r s ta t o r a s s e m b ly

(6 8 )

–

P l u g a s s e m b ly

(2 1 ) (2 2 )

– –

E x t e r n a l r e t a i n i n g r i n g S p r in g a n d r e t a in e r a s s e m b ly

(6 9 ) (7 0 )

– –

O - r in g , 1 6 .4 m m P lu g

(2 3 )

–


(7 1 )

–

P l u g a s s e m b ly

(2 4 )

–

P is to n s e a lr in g , 2 5 8 . 7 m m

(7 2 )

–

P lu g

(2 5 ) (2 6 )

– –

I n t e r n a l s e a lr in g , 1 4 0 . 3 m m R o lle r b e a r in g c u p

(7 3 ) (7 4 )

– –

O - r in g , 1 6 .4 m m S p r in g

(2 7 )

–

R e t a r d e r s ta t o r

(7 5 )

–

R e g u la t o r v a lv e

(2 8 )

–

O - r in g

(7 6 )

–

R e t a in e r p in

(2 9 ) (3 0 )

– –

S e a l r in g , r o t a t in g G a s k e t

(7 7 ) (7 8 )

– –

S o l e n o id a n d c o n n e c t o r a s s e m b ly S o l e n o i d , v a r ia b l e b l e e d

(3 1 )

–

R o to r

(7 9 )

–

O - r in g , s q u a r e c u t

(3 2 )

–

S e a l r in g , r o t a t in g

(8 0 )

–

O - r in g

(3 3 )

–

B o l t , M 1 0 x 1 . 5 x 9 0 ( 3 ) , C

(8 1 )

–

B o l t , M 8 x 1 . 2 5 x 6 5 , C

(3 4 ) (3 5 )

– –

R e t a r d e r h o u s in g a s s e m b ly T e m p e r a t u r e s e n s o r a s s e m b ly

(8 2 ) (8 3 )

– –

P l u g a s s e m b ly P l u g , C

(3 6 )

–

O - r in g

(8 4 )

–

O - r in g

(3 7 ) (3 8 )

– –

T e m p e r a t u r e s e n s o r b r a c k e t B o l t , M 8 x 1 . 2 5 x 2 0 , C

(8 5 ) (8 6 )

– –

S h i p p in g c o v e r G a s k e t

(3 9 )

–

S p e e d s e n s o r a s s e m b ly

(8 7 )

–

J u m p e r m a n if o ld

(4 0 ) (4 1 )

– –

O - r in g S p e e d s e n s o r r e t a in e r

(8 8 ) (8 9 )

– –

R e m o t e m a n if o ld B o l t , M 1 0 x 1 . 5 x 3 0 ( 4 ) , B

(4 2 ) (4 3 )

– –

B o l t , M 8 x 1 . 2 5 x 2 0 , C R e t a in in g r in g

(4 4 )

–

F lo w

(4 5 ) (4 6 )

– –

R o lle r b e a r in g c u p R e t a r d e r h o u s in g s u b a s s e m b ly

(4 7 )

–

T a c h o g r a p h p lu g

(4 8 )

–

W a s h e r , p lu g

(1 0 ) (1 1 )

–

D ia D ia

T o rq u e

v a lv e p lu g

F o l d o u t 1 1 A

C o p y r ig h t ©

I D

I D

N ∙m

lb

f t

A

9 0 – 1 1 0

6 6 – 8 1

B

5 1 – 6 1

3 8 – 4 5

C

2 4 – 2 9

1 8 – 2 1

2 0 0 9 A l li s o n T r a n s m is s io n , I n c .

S E R V IC E

T o rq u e

M A N U A L — 3 0 0 0 P r o d u c t F a m i l y — A l l i s o n 4 t h G e n e r a t i o n C o n t r o ls — V O C A T IO N A L M O D E L S N ∙m

lb

f t

D

6 0 – 6 7

4 4 – 5 0

E

7 4 – 8 8

5 5 – 6 5

F

1 0 – 1 3

7 – 1 0

C o p y r ig h t ©

2 0 0 9


F o l d o u t 1 1 A

S E R V IC E

F o l d o u t 1 1 A


C o p y r ig h t ©


F O L D O U T 1 1 A

F o ld o u t 1 1 A . R e t a rd e r a n d

P 3

P la n e ta r y

M o d u le —


V i e w

S E R V IC E


L e g e n d f o r F o ld o u t 1 1 B

C o p y r ig h t ©

Is O n

2 0 0 9

T h e O p p o s it e S i d e O f T h i s P a g e .


F o l d o u t 1 1 B


S E R V IC E

L e g e n d (1 )

–

R e a r c o v e r g a s k e t

(2 ) (3 )

– –

B o l t , M 1 2 x 1 . 7 x 4 5 ( 1 9 ) , A R e a r s u p p o r t b r a c k e t

(4 )

–

R e a r c o v e r a n d P 3 p la n e t a r y m o d u le

(5 ) (6 )

– –

P 3 p la n e t a r y c a r r ie r a s s e m b ly O u t p u t s h a f t a s s e m b ly

(7 ) (8 )

– –

B u s h in g O u tp u t s h a ft

(9 )

–


(1 0 ) (1 1 )

–

I n d e x in g r i n g S p r i n g p in , 5 x 1 2

(1 2 )

–

P 3 p l a n e t a r y c a r r ie r

(1 3 )

–

C o n e a n d r o lle r b e a r in g a s s e m b ly

(1 4 )

–

O u tp u t s p a c e r

(1 5 ) (1 6 )

– –

E x t e r n a l r e t a i n i n g r i n g P 3 p la n e t a r y s p in d le ( 4 )

(1 7 )

–

T h r u s t w a s h e r ( 4 )

(1 8 ) (1 9 )

– –

P 3 p in io n g e a r ( s e t o f f o u r g e a r s ) R o lle r b e a r in g a s s e m b ly ( 8 )

(2 0 )

–

P 3 t h r u s t w a s h e r ( 4 )

(2 1 ) (2 2 )

– –

R e a r c o v e r a s s e m b ly E x t e r n a l r e t a i n i n g r i n g

(2 3 )

–

S p r in g a n d r e t a in e r a s s e m b ly

(2 4 )

–


(2 5 ) (2 6 )

– –

P is to n s e a lr in g , 2 8 1 m m ( 1 1 .0 6 in c h ) d i a I n t e r n a l s e a l r in g , 1 4 0 m m ( 5 . 5 1 in c h ) d i a

(2 7 )

–

R o lle r b e a r in g c u p

(2 8 )

–

R e a r c o v e r

(2 9 ) (3 0 )

– –

S p e e d s e n s o r a s s e m b ly O - r in g

(3 1 )

–


(3 2 )

–

B o l t , M 8 x 1 . 2 5 x 2 0 , B

(3 3 )

–

O u tp u t s p e e d s ig n a l w h e e l

(3 4 ) (3 5 )

– –

R o lle r b e a r in g c u p C o n e a n d r o lle r b e a r in g a s s e m b ly

(3 6 )

–

B e l le v i lle s p r in g w a s h e r

(3 7 ) (3 8 )

– –

B e a r i n g r e t a i n e r n u t , M 7 0 x 2 0 , C O il s e a l a s s e m b ly

(3 9 )

–

T a c h o g r a p h p lu g

(4 0 ) (4 1 )

– –

W a s h e r R e a r c o v e r

(4 2 )

–

S h ip p in g c o v e r

–

T o rq u e

N ∙m

lb

f t

f o r F o l d o u t 1 1 B

A

9 0 – 1 1 0

6 6 – 8 1

B

2 4 – 2 9

1 8 – 2 1

C

7 4 – 8 8

5 5 – 6 5

F o l d o u t 1 1 B

C o p y r ig h t ©


F O L D O U T 1 1 B

F o ld o u t 1 1 B . R e a r C o v e r a n d

P 3

P la n e ta ry

M o d u le —


V i e w

S E R V IC E



C o p y r ig h t ©

2 0 0 9



F o ld o u t 1 2

S E R V IC E


L e g e n d


1 2 - 1 A

–

K e n t-M o o re

T o o ls

(1 ) (2 )

– –

J 3 8 5 4 7 F o r w a r d / r e a r o u t p u t s e a l in s t a l le r J 3 8 5 6 8 B e a r in g c u p in s t a lle r s

(3 )

–

J 3 8 5 6 8 - 1 D r i v e / d r iv e n b e a r in g c u p i n s t a l le r

(4 )

–

J 3 8 5 6 8 - 2 I d l e r b e a r in g c u p in s t a lle r

(5 )

–

J 3 8 5 6 8 - 3 F o r w a r d / r e a r o u t p u t b e a r in g c u p i n s t a l l e r

(6 )

–

J 3 8 5 6 9 P 3 c a r r ie r / C 6 /C 7 h o u s in g b u s h in g i n s t a l l e r

(2 3 )

–

I d le r b e a r in g r e t a in e r s h im , 0 . 0 7 6 m m i n c h )

(2 4 )

–

I d le r c o v e r g a s k e t

(2 5 )

–

T a p e r e d r o l le r b e a r in g c u p

(2 6 )

–


(2 7 ) (2 8 )

– –

O u tp u t o il s e a l T a p e r e d r o l le r b e a r in g c u p

(2 9 ) (3 0 )

– –

O u tp u t h o u s in g T a p e r e d r o l le r b e a r in g c u p

(3 1 )

–

B o l t , M 1 0 x 1 . 5 x 3 5 ( 8 ) , A

(7 )

–

J 3 8 5 7 2 T r a n s f e r c a s e h o ld in g fi x t u r e

(3 2 )

–

M a n if o ld a s s e m b ly

(8 )

–

J 3 8 5 7 3 C 6 s p rin g c o m p r e s s o r

(3 3 )

–

(9 ) – (1 0 ) –

J 3 8 5 7 9 B e a r in g in s ta lle r s J 3 8 5 7 9 - 1 D r i v e / d r i v e n b e a r i n g i n s t a l l l e r

(3 4 )

–

(1 1 )

J 3 8 5 7 9 - 2 F o r w a r d / r e a r o u t p u t a n d id le r b e a r in g i n s t a l l e r

O in O in

(3 5 )

J 3 8 5 4 7 F r o n t a n d r e a r o u t p u t s e a l in s t a lle r J 3 9 6 2 3 B e a r i n g e n d p la y c h e c k e r

–

(1 2 ) (1 3 )

– –

1 2 - 2 (1 )

–

B o l t , M 1 0 x 1 . 5 x 5 5 ( 8 ) , A

(2 ) (3 )

– –

(4 )

–

O In in In in

(5 )

–

I n p u t b e a r i n g r e t a i n e r s h im , 0 . 0 7 6 m m i n c h )

(6 )

–

T r a n s f e r c a s e h o u s in g a s s e m b ly

(7 ) (8 )

– –

T r a n s f e r c a s e h o u s in g T r a n s fe r c a s e c o v e r

(9 )

–

T a p e r e d r o lle r b e a r in g c u p

(1 0 ) (1 1 )

– –

il p p u c h p u c h

u m p a s s e m b ly t b e a r i n g r e t a i n e r s h im , 0 . 2 5 4 m m ) t b e a r i n g r e t a i n e r s h im , 0 . 1 2 7 m m )

( 0 . 0 1 0 ( 0 . 0 0 5 ( 0 . 0 0 3

u c u c

tp u t b e a r in g r e ta in e r s h im , 0 . 2 5 4 m m h ) tp u t b e a r in g r e ta in e r s h im , 0 . 1 2 7 m m h )

( 0 . 0 1 0

–

O u tp u t b e a r in g r e ta in e r s h im , 0 . 0 7 6 m m i n c h )

( 0 . 0 0 3

(3 6 )

–


(3 7 ) (3 8 )

– –

T a p e r e d r o l le r b e a r in g c u p T a p e r e d r o l le r b e a r in g c u p

(3 9 ) (4 0 )

– –

O u tp u t h o u s in g T a p e r e d r o l le r b e a r in g c u p

(4 1 )

–

O u tp u t o il s e a l

(4 2 )

–

B o l t , M 1 0 x 1 . 5 x 1 0 0 ( 1 5 ) , A T o rq u e A

T a p e r e d r o lle r b e a r in g c u p C 6 c lu t c h h o u s i n g a s s e m b ly

(1 2 ) (1 3 )

– –

I n t e r n a l r e t a i n i n g r i n g S p r in g r e t a in e r a s s e m b l y

(1 4 )

–

C 6 p is t o n

(1 5 ) (1 6 )

– –

O D s e a lr in g I D s e a lr in g

(1 7 )

–

B o l t , M 1 0 x 1 . 5 x 1 0 0 ( 1 5 ) , A

(1 8 )

–

B o l t , M 1 0 x 1 . 5 x 4 0 ( 5 ) , A

(1 9 )

–

I d le r c o v e r

(2 0 ) (2 1 )

– –

I d l e r c o v e r o - r in g I d l e r b e a r in g r e t a in e r s h im , 0 . 2 5 4 m m i n c h )

(2 2 )

–

I d l e r b e a r in g r e t a in e r s h im , 0 . 1 2 7 m m i n c h )

F o l d o u t 1 2

( 0 . 0 1 0 ( 0 . 0 0 5

C o p y r ig h t ©

( 0 . 0 0 3


N ∙m 5 1 – 6 1

lb

( 0 . 0 0 5

ft

3 8 – 4 5

F O L D O U T 1 2

F o ld o u t 1 2 - 1 . T r a n s f e r C a s e S p e c ia l T o o l s — D i s a s s e m b l e d V i e w

F o ld o u t 1 2 - 2 . T r a n s f e r C a s e , S p e c i a l D i s a s s e m b l y /A s s e m b l y I n s t r u c t i o n s —

D i s a s s e m b l e d V i e w

S E R V IC E



C o p y r ig h t ©

2 0 0 9



F o ld o u t 1 3

S E R V IC E


L e g e n d


(1 )

–

T r a n s f e r c a s e m o d u le

(4 4 )

–

F r o n t y o k e a s s e m b ly ( 1 6 T Y S )

(2 ) (3 )

– –

B o l t , M 1 0 x 1 . 5 x 4 0 ( 1 5 ) , A T r a n s m is s io n s h a ft a d a p te r

(4 5 ) (4 6 )

– –

B o l t , M 1 0 x 1 . 5 x 4 0 ( 1 5 ) , A O u tp u t o il s e a l

(4 )

–

B o l t , M 1 0 x 1 . 5 x 5 5 ( 8 ) , A

(4 7 )

–

T a p e r e d r o l le r b e a r in g c o n e

(5 ) (6 )

– –

O il p u m p a s s e m b ly P r e s s u r e r e lie f v a lv e

(4 8 ) (4 9 )

– –

T a p e r e d r o l le r b e a r in g c u p O u tp u t h o u s in g

(7 ) (8 )

– –

S p r in g P l u g , D

(5 0 ) (5 1 )

– –

(9 )

–

S p rin g p in

(1 0 ) (1 1 ) (1 2 )

– – –

I n p u t b e a r in g r e t a in e r s h im , 0 . 2 5 4 m m i n c h )

( 0 . 0 1 0

(5 2 )

–

In in In in

( 0 . 0 0 5

(5 3 )

–

( 0 . 0 0 3

(5 4 )

–

O Id in Id in Id in O

(5 5 )

–


p u c h p u c h

t b e a r in g r e t a in e r s h im , 0 . 1 2 7 m m ) t b e a r in g r e t a in e r s h im , 0 . 0 7 6 m m )

u tp u t le r b e c h ) le r b e c h ) le r b e c h ) u tp u t

h o u s in g g a s k e t a r in g r e t a in e r s h im , 0 . 2 5 4 m m

( 0 . 0 1 0

a r in g r e t a in e r s h im , 0 . 1 2 7 m m

( 0 . 0 0 5

a r in g r e t a in e r s h im , 0 . 0 7 6 m m

( 0 . 0 0 3

b e a r in g s s p a c e r

(1 3 )

–

T r a n s f e r c a s e h o u s in g a s s e m b l y

(5 6 )

–


(1 4 )

–

T r a n s f e r c a s e h o u s in g

(5 7 )

–

F r o n t o u t p u t s h a f t

(1 5 ) (1 6 )

– –

D o w e l S p l it li n e g a s k e t ( f r o n t a n d r e a r c a s e s )

(5 8 ) (5 9 )

– –

C 7 c lu t c h h o u s i n g a s s e m b l y C 7 c lu tc h h u b

(1 7 ) (1 8 )

– –

T a p e r e d r o lle r b e a r in g c u p T a p e r e d r o lle r b e a r in g c o n e

(6 0 ) (6 1 )

– –

I n t e r n a l r e t a i n i n g r i n g C 7 c lu t c h b a c k p l a t e

(1 9 )

–

D r iv e g e a r ( 3 0 T )

(6 2 )

–

C 7 f r ic t io n p l a t e

(2 0 ) (2 1 )

– –

T a p e r e d r o lle r b e a r in g c o n e T a p e r e d r o lle r b e a r in g c u p

(6 3 ) (6 4 )

– –

C 7 r e a c tio n p la t e C 7 p is t o n

(2 2 ) (2 3 )

– –

B o l t , M 1 0 x 1 . 5 x 4 0 ( 5 ) , A I d le r c o v e r

(6 5 ) (6 6 )

– –

E x t e r n a l s e a l r in g I n t e r n a l s e a l r in g

(2 4 )

–

I d l e r c o v e r o - r in g

(6 7 )

–

C 7 c lu t c h h o u s in g

(2 5 )

–


( 0 . 0 1 0

(6 8 ) (6 9 )

– –

B u s h in g , 5 3 .1 0 m m ( 2 . 0 8 in c h ) d ia B a ll, 6 . 3 5 m m ( 0 . 2 5 0 in c h ) d ia

(2 6 )

–


( 0 . 0 0 5

(7 0 )

–

M a n i f o l d s e a l r in g

(7 1 )

–

B o l t , M 1 0 x 1 . 5 x 3 5 ( 8 ) , A

(2 7 )

–


( 0 . 0 0 3

(7 2 )

–

M a n if o ld a s s e m b ly

(2 8 )

–


(2 9 )

–

E le c t r i c a l c o n n e c t o r p l a t e

(7 3 ) (7 4 )

– –

M a n if o ld B a ll, 0 . 2 1 8 d ia

(3 0 ) (3 1 )

– –

E le c t r i c a l c o n n e c t o r g a s k e t E le c t r i c a l c o n n e c t o r a s s e m b l y

(7 5 )

–


( 0 . 0 1 0

(7 6 )

–

–

B o l t , M 8 x 1 . 2 5 x 2 5 ( 4 ) , B


( 0 . 0 0 5

(3 2 ) (3 3 ) (3 4 )

– –

L u b e h o l e p l u g ( 2 ) , C O r i fi c e d p l u g ( l u b e h o l e ) ( 2 ) , D

(7 7 )

–


( 0 . 0 0 3

(3 5 )

–

P l u g a s s e m b l y ( 2 ) , D

(7 8 )

–


(3 6 )

–

O - r in g ( 9 . 2 5 I D )

(7 9 )

–


(3 7 )

–

T a p e r e d r o lle r b e a r in g c u p

(8 0 )

–

D r iv e n g e a r

(3 8 ) (3 9 )

– –

T a p e r e d r o lle r b e a r in g c o n e I d le r g e a r ( 3 7 T )

(8 1 ) (8 2 )

– –

T a p e r e d r o l le r b e a r in g c o n e T a p e r e d r o l le r b e a r in g c u p

(4 0 ) (4 1 )

– –

T a p e r e d r o lle r b e a r in g c o n e T a p e r e d r o lle r b e a r in g c u p

(8 3 ) (8 4 )

– –

L u b e c h a r g in g p u m p f r o n t c o v e r L u b e c h a r g in g p u m p d r iv e g e a r

(4 2 ) (4 3 )

– –

F r o n t o u t p u t s h a f t n u t , E F la t w a s h e r

(8 5 ) (8 6 )

– –

L u b e c h a r g in g p u m p d r iv e n g e a r L u b e c h a r g in g p u m p r e v e r s in g r i n g

F o l d o u t 1 3

C o p y r ig h t ©



S E R V IC E

(8 7 )

–

L u b e c h a r g in g p u m p r e a r c o v e r

(8 8 )

–

C o n n e c t o r n u t , F T o rq u e

N ∙m

A

5 1 – 6 1

B

5 – 8

C

2 4 – 2 9

D

1 2 – 1 4

E

6 1 0 – 8 1 5

F

2 .7 3 – 4 .0 9

lb

ft

3 8 – 4 5 4 – 6

1 8 – 2 1 9 – 1 0 4 5 0 – 6 0 0 2 4 – 3 6 lb in .

C o p y r ig h t ©

2 0 0 9


F o ld o u t 1 3

S E R V IC E

F o l d o u t 1 3


C o p y r ig h t ©


F O L D O U T 1 3

F o l d o u t 1 3 . F r o n t M a in

T ra n s fe r C a s e —


V i e w

S E R V IC E



C o p y r ig h t ©

2 0 0 9



F o ld o u t 1 4

S E R V IC E


L e g e n d


(1 )

–

T r a n s f e r c a s e h o u s in g a s s e m b ly

(4 9 )

–

I d le r c o v e r

(2 ) (3 )

– –

T r a n s fe r c a s e c o v e r B e a r in g r e t a in e r

(5 0 ) (5 1 )

– –

B o l t , M 1 0 x 1 . 5 x 4 0 ( 5 ) , A O r ifi c e p lu g , 5 m m ( 0 . 1 9 7 in c h )

(4 )

–

B o l t , M 1 0 x 1 . 5 x 3 5 ( 8 ) , A

(5 2 )

–

D r a i n p l u g a s s e m b l y , D

(5 ) (6 )

– –

C 6 c l u t c h h o u s i n g a s s e m b ly I n t e r n a l r e t a i n i n g r i n g

(5 3 ) (5 4 )

– –

O - r in g B e a r in g r e t a in e r

(7 ) (8 )

– –

C 6 h u b T h r u s t b e a r in g

(5 5 ) (5 6 )

– –

B o l t , M 1 0 x 1 . 5 x 3 5 ( 8 ) , A P 4 c a r r ie r a s s e m b ly

(9 )

–

C 6

b a c k p la te

(5 7 )

–

P 4 c a r r ie r

–

C 6 f r i c t io n p l a t e C 6 r e a c tio n p la t e

(5 8 ) (5 9 )

– –

P la n e t a r y p in io n s h a f t s e t s c re w P 4 s p in d le

(1 2 )

–

E x t e r n a l r e t a i n i n g r i n g

(6 0 )

–

R o lle r b e a r in g s

(1 3 )

–

S p r in g r e t a in e r a s s e m b l y

(6 1 )

–

P i n io n g e a r ( 1 7 T )

(1 4 )

–

C 6 p is t o n

(6 2 )

–

T h r u s t w a s h e r

(1 5 ) (1 6 )

– –

C 6 O D s e a lr in g C 6 ID s e a lr in g

(6 3 ) (6 4 )

– –

S u n g e a r E x t e r n a l r e t a i n i n g r in g

(1 7 )

–

C 6 h o u s in g a s s e m b ly w it h b u s h in g

(6 5 )

–

R in g g e a r ( 5 9 T )

(1 8 ) (1 9 )

– –

C 6 h o u s in g a s s e m b ly C 6 h o u s in g

(6 6 ) (6 7 )

– –

R e a r o u tp u t s h a ft T a p e r e d r o l le r b e a r in g c o n e

(2 0 )

–

C 6 s le e v e

(6 8 )

–


(2 1 ) (2 2 )

– –

B u s h in g C 6 h o u s in g g a s k e t

(6 9 ) (7 0 )

– –

(2 3 )

–

B o l t , M 1 0 x 1 . 5 x 1 0 0 ( 1 5 ) , A

O u t p u t b e a r in g s s p a c e r O u tp u t b e a r in g r e ta in e r s h im i n c h )

(2 4 )

–

B o l t , M 1 0 x 1 . 5 x 4 0 ( 2 ) , A

(7 1 )

–

(2 5 ) (2 6 )

– –

L u b e h o l e p l u g , B O r i fi c e d p l u g ( l u b e h o l e ) , C

(7 2 )

(2 7 )

–

P l u g a s s e m b l y , C

(2 8 )

–

O - r in g ( 9 . 2 5 I D )

(2 9 ) (3 0 )

– –

C o n tr o l v a lv e b o d y a s s e m b ly C o n tr o l b o d y

(3 1 )

–

V a lv e

(3 2 )

–

S p r in g

(3 3 )

–

S to p

(3 4 ) (3 5 )

– –

P in S o le n o id , N / C

(3 6 )

–

O - r in g , 0 . 5 5 1 I D

(3 7 ) (3 8 )

– –

O - r in g , 0 . 3 6 4 I D V a lv e

(3 9 )

–

S o le n o id s p r in g

(4 0 ) (4 1 )

– –

P in B o l t , M 8 x 1 . 2 5 x 5 0 ( 6 ) , B

(4 2 ) (4 3 )

– –

C o n tr o l c o v e r g a s k e t C o n tr o l c o v e r

(4 4 )

–

(4 5 ) (4 6 )

(1 0 ) (1 1 )

–

m o d u la t in g

( 3 ) , D

0 .2 5 4 m m

( 0 . 0 1 0

O u tp u t b e a r in g r e ta in e r s h im i n c h )

0 .1 2 7 m m

( 0 . 0 0 5

–

O u tp u t b e a r in g r e ta in e r s h im i n c h )

0 .0 7 6 m m

( 0 . 0 0 3

(7 3 ) (7 4 )

– –

O u tp u t h o u s in g g a s k e t O u tp u t h o u s in g

(7 5 )

–

B o l t , M 1 0 x 1 . 5 x 4 0 ( 6 ) , A

(7 6 )

–


(7 7 )

–


(7 8 ) (7 9 )

– –

O u tp u t o il s e a l R e a r y o k e a s s e m b ly ( 1 6 T Y S )

(8 0 )

–

F la t w a s h e r

(8 1 )

–

R e a r o u t p u t s h a f t n u t , E

(8 2 )

–

B o l t , M 1 0 x 1 . 5 x 1 0 0 ( 9 ) , A T o rq u e

N ∙m

lb

f t

A

5 1 – 6 1

3 8 – 4 5

B

2 4 – 2 9

1 8 – 2 1

C

1 2 – 1 4

9 – 1 0

B o l t , M 8 x 1 . 2 5 x 3 0 ( 1 0 ) , B

D

2 5 – 3 5

1 8 -2 6

– –

S p e e d s e n s o r B o l t , M 8 x 1 . 2 5 x 2 5 ( 2 ) , B

E

6 1 0 – 8 1 5

(4 7 )

–


(4 8 )

–

I d l e r c o v e r o - r in g

F o l d o u t 1 4

C o p y r ig h t ©


4 5 0 – 6 0 0

F O L D O U T 1 4

F o l d o u t 1 4 . R e a r M a in

T ra n s fe r C a s e —


V i e w

S E R V IC E



C o p y r ig h t ©

2 0 0 9



F o ld o u t 1 5

S E R V IC E


L e g e n d 1 5 - 2

f o r F o l d o u t 1 5 (4 7 ) (4 8 )

– –

B r a c k e t B o l t , M 6 x 1 . 0 x 4 5 ( 2 ) , A

(1 )

–


(2 ) (3 )

– –

S u c t i o n fi lt e r a s s e m b l y k it B o l t , M 6 x 1 . 0 x 3 0 , A

(4 9 )

–

F a c e s e a l

(5 0 )

–

A c c u m u la t o r s p r in g

(4 )

–

S u c t i o n fi lt e r a s s e m b l y

(5 1 )

–

A c c u m u la t o r p l u g ( 2 )

(5 )

–

S u c t io n fi lt e r

(6 ) (7 )

– –

F a c e s e a l S u c t i o n fi lt e r g a s k e t

(5 2 ) (5 3 )

– –

A c c u m u la t o r p l u g ( 2 ) A c c u m u la t o r s p r in g ( 2 )

(5 4 )

–

S w it c h a s s e m b ly

(8 ) (9 )

– –

C o n tr o l h a r n e s s a s s e m b ly C o n n e c t o r a s s e m b ly

(5 5 ) (5 6 )

– –

S w it c h B r a c k e t

E le c t r o n i c c o n n e c t o r

(5 7 )

–

B o l t , M 6 x 1 . 0 x 9 5 ( 1 2 ) , A

S e a l

(5 8 )

–

S o l e n o id b o d y a s s e m b ly

(5 9 ) (6 0 )

– –

B o d y A s s e m b ly v a lv e a n d p in B o d y

(6 1 )

–

P in ( 3 )

(1 0 ) (1 1 )

– –

(1 2 )

–

S e a lr in g

(1 3 ) (1 4 )

– –

S t a n d o ff a s s e m b ly C a v it y p lu g

(1 5 )

–

B o l t , 2 0 F c o n n e c t o r , C

(6 2 )

–

V a r i a b l e b l e e d s o le n o i d ( T C C )

(1 6 ) (1 7 )

– –

T e m p e r a tu r e s e n s o r ( O I L T ) C o n n e c t o r a s s e m b ly

(6 3 )

–

O - r in g

(1 8 )

–

C o n n e c t o r, 2 - W a y

(6 4 ) (6 5 )

– –

O - r in g T C C v a lv e

(1 9 )

–

P in t e r m in a l

(6 6 )

–

S p r in g

(2 0 )

–

P in t e r m in a l

(2 1 ) (2 2 )

– –

S e c o n d a r y lo c k C o n n e c t o r A s s e m b ly ( O L S )

(6 7 ) (6 8 )

– –

V a r i a b l e b l e e d s o le n o i d ( P C S 1 ) O - r in g

(6 9 )

–

O - r in g

(2 3 )

–

T e r m in a l

(7 0 )

–

P C S 1 v a lv e

(2 4 ) (2 5 )

– –

T e r m in a l C o n n e c t o r , 2 - w a y

(7 1 )

–

S p r in g

(2 6 )

–

C o n n e c t o r A s s e m b ly ( S S 1 )

(7 2 ) (7 3 )

– –


(2 7 )

–

T e r m in a l

(7 4 )

–

O - r in g

(2 8 )

–

T e r m in a l

(2 9 ) (3 0 )

– –

C o n n e c t o r , 2 - w a y C h a n n e l

(7 5 ) (7 6 )

– –

P C S 2 v a lv e S p r in g

(7 7 )

–

C lip

(3 1 )

–

S o le n o id c o n n e c t o r a s s e m b ly ( S S 2 )

(7 8 )

–

D ia g n o s t ic v a lv e

(3 2 )

–

C o n n e c t o r , 2 - w a y

(7 9 )

–

S p r in g

(3 3 ) (3 4 )

– –

T e r m in a l T e r m in a l

(8 0 ) (8 1 )

– –


(3 5 )

–

2 - W a y s o l e n o id c o n n e c t o r ( P C S 4 )

(3 6 )

–


(8 2 ) (8 3 )

– –

O - r in g P C S 3 v a lv e

(3 7 ) (3 8 )

– –

2 - W a y s o l e n o id c o n n e c t o r ( P C S 6 ) 2 - W a y s o l e n o id c o n n e c t o r ( P C S 1 )

(8 4 )

–

S p r in g

(8 5 )

–

V a r i a b l e b l e e d s o le n o i d ( P C S 4 )

(3 9 )

–

2 - W a y c o n n e c t o r ( C 3 p r e s s u r e s w it c h )

(8 6 )

–

O - r in g

(4 0 )

–

T e r m in a l

(4 1 ) (4 2 )

– –

T e r m in a l C o n n e c t o r , 2 - w a y

(8 7 ) (8 8 )

– –

O - r in g P C S 4 v a lv e

(8 9 )

–

S p r in g

(4 3 ) (4 4 )

– –

2 - W a y s o le n o id c o n n e c t o r ( T C C ) 2 - W a y s o l e n o id c o n n e c t o r ( P C S 2 )

(9 0 )

–

V a r i a b l e b l e e d s o le n o i d ( M a i n M o d )

(4 5 )

–


(9 1 ) (9 2 )

– –

O - r in g O - r in g

(4 6 )

–

S h o u l d e r b o l t M 6 x 1 . 0 x 4 5 ( 3 ) , B

(9 3 )

–

B o l t , M 6 x 1 . 0 x 2 0 ( 2 ) , A

F o l d o u t 1 5

C o p y r ig h t ©


S E R V IC E


(9 4 )

–

S p e e d s e n s o r

(1 4 4 ) –

O i l t r a n s f e r p l a t e

(9 5 ) (9 6 )

– –

B o l t , M 6 x 1 . 0 x 6 0 ( 2 ) , A S e p a r a t o r p la t e

(1 4 5 ) – (1 4 6 ) –

P lu g a s s e m b ly O - r in g

(9 7 )

–

M a in v a lv e b o d y a s s e m b ly

(1 4 7 ) –

P lu g a s s e m b ly

(9 8 ) (9 9 )

– –

R e te n t i o n p in 5 O D L o c k u p v a lv e

(1 4 8 ) – (1 4 9 ) –

O - r in g P r e s s u r e t a p p l u g

x 4 3

(1 0 0 ) –

S p r in g

(1 5 0 ) –

O i l t r a n s f e r p l a t e a s s e m b l y

(1 0 1 ) –

V a l v e s to p

(1 5 1 ) –

D o w e l p in ( 2 )

(1 0 2 ) –

R e te n t io n p in 3 O D

(1 5 2 ) –

O i l t r a n s f e r p l a t e

(1 0 3 ) – (1 0 4 ) –

L u b e r e g u l a t o r v a l v e S p r in g

(1 5 3 ) – (1 5 4 ) –

P lu g a s s e m b ly O - r in g

(1 0 5 ) –

V a l v e s to p

(1 5 5 ) –

P lu g a s s e m b ly

(1 0 6 ) – (1 0 7 ) –

R e te n t io n p in 5 O D x 4 3 M a i n r e g u l a t o r v a l v e

(1 5 6 ) – (1 5 7 ) –

P lu g P lu g

(1 0 8 ) –

S p r in g

(1 5 8 ) –

F il t e r c o v e r ( 2 )

(1 0 9 ) –

V a l v e s to p

(1 5 9 ) –

G a s k e t ( 2 )

(1 1 0 ) –

R e te n tio n p in , 5 O D

(1 6 0 ) –

O - r in g ( 2 )

(1 1 1 ) – (1 1 2 ) –

C o n t r o l m a i n v a lv e S p r in g

(1 6 1 ) – (1 6 2 ) –

O - r in g ( 2 ) O i l fi l t e r

(1 1 3 ) – (1 1 4 ) –

C lip R e te n tio n p in , 2 .5 O D

(1 6 3 ) – (1 6 4 ) –

B o l t , M 1 0 x 1 . 5 x 5 5 ( 3 2 ) , E B o l t , M 1 0 x 1 . 5 x 1 0 0 ( 2 5 , 4 i n c h s u m p ) , E

(1 1 5 ) – (1 1 6 ) –

S o le n o i d a s s e m b ly O - r in g

(1 6 5 ) – (1 6 6 ) –

F il t e r c o v e r g a s k e t ( 2 ) C 6 s o le n o id m o d u le a s s e m b l y ( 7 - s p e e d )

(1 1 7 ) – (1 1 8 ) –

O - r in g C o n t r o l v a lv e b o d y

(1 6 7 ) – (1 6 8 ) –

S p e e d n u t, p u s h o n S o l e n o i d p r o t e c t i v e p l a t e

(1 1 9 ) –


x 4 3

(1 6 9 ) –

S o le n o id , C 6

(1 2 0 ) –


x 4 3

(1 7 0 ) –

O - r in g

(1 2 1 ) –


x 4 3

(1 7 1 ) –

O - r in g

(1 2 2 ) – (1 2 3 ) –

C 2 l a t c h v a lv e S p r in g

(1 7 2 ) – (1 7 3 ) –

V a l v e S p r in g

(1 2 4 ) –

V a l v e s to p

(1 7 4 ) –

P in

(1 2 5 ) – (1 2 6 ) –

R e te n tio n p in , 5 O D x 4 3 E x h a u s t b a c k fi ll v a l v e

(1 7 5 ) – (1 7 6 ) –

B o d y A c c u m u l a t o r r e t a i n i n g b r a c k e t

(1 2 7 ) –

S p r in g

(1 7 7 ) –

A c c u m u l a t o r s p r in g

(1 2 8 ) –

V a l v e s to p

(1 7 8 ) –

S p r in g

(1 2 9 ) –

C 1 l a t c h v a lv e

(1 7 9 ) –

V a l v e

(1 3 0 ) – (1 3 1 ) –

S p r in g V a l v e s to p

(1 8 0 ) – (1 8 1 ) –

S o le n o i d O - r in g

(1 3 2 ) –

R e te n tio n p in , 5 O D

x 4 3

(1 8 2 ) –

O - r in g

(1 3 3 ) – (1 3 4 ) –

C o n v e r t e r r e g u l a t o r v a l v e S p r in g

(1 8 3 ) – (1 8 4 ) –

B r a c k e t S c r e w

(1 3 5 ) –

V a l v e s to p

(1 8 5 ) –

B o l t , M 6 x 1 . 0 x 6 0 ( 4 ) , A

(1 3 6 ) –

B o l t , M 6 x 1 . 0 x 4 5 ( 2 ) , B

(1 8 6 ) –

B r a c k e t

(1 3 7 ) –

O il le v e l s e n s o r a s s e m b ly

(1 3 8 ) – (1 3 9 ) –

F e r r u l e V it o n ® ( 2 ) S e p a r a t o r p l a t e

(1 4 0 ) –

C h a n n e l p la t e g a s k e t

(1 4 1 ) – (1 4 2 ) – (1 4 3 ) –

x 4 5

x 4 3

x 4 0

T o rq u e

N ∙m

A

1 0 – 1 3

O il t r a n s f e r p l a t e a s s e m b l y

B

5 – 8

D r a in p lu g D o w e l p in ( 2 )

C

2 .5 – 3 .5

C o p y r ig h t ©

2 0 0 9


lb

f t

7 – 1 0 4 – 6

2 2 – 3 1 lb in c h

F o ld o u t 1 5

S E R V IC E

T o rq u e

M A N U A L — 3 0 0 0 P r o d u c t F a m i l y — A l l i s o n 4 t h G e n e r a t i o n C o n t r o ls — V O C A T IO N A L M O D E L S N ∙m

lb

f t

D

2 5 – 3 2

1 8 – 2 4

E

5 1 – 6 1

3 8 – 4 5

F o l d o u t 1 5

C o p y r ig h t ©


F O L D O U T 1 5

F o ld o u t 1 5 -1 . C o n tro l V a lv e M o d u le —


F o ld o u t 1 5 -2 . C o n tr o l V a lv e M o d u le —


S E R V IC E



C o p y r ig h t ©

2 0 0 9



F o ld o u t 1 6

S E R V IC E


L e g e n d


1 6 - 2

(4 5 ) (4 6 )

– –

C o n n e c t o r C o n n e c t o r A s s e m b ly , 2 - W a y ( T C C )

(1 )

–

V a lv e A s s e m b ly , C o n tr o l

(2 ) (3 )

– –

F i lt e r A s s e m b l y K it , S u c t io n G a s k e t , S u c tio n F i lt e r

(4 7 )

–

C o n n e c t o r A s s e m b ly , 2 - W a y ( P C S 1 )

(4 8 )

–


(4 )

–

F i lt e r A s s e m b ly , S u c t io n

(4 9 )

–

B o lt , M 6 x 1 .0 x 4 5 ( 3 )

(5 )

–

F i lt e r A s s e m b ly , S u c t io n

(6 ) (7 )

– –

S e a l, F a c e B o lt, M 6 x 1 .0 x 3 0 ( 3 )

(5 0 ) (5 1 )

– –

B r a c k e t B o lt , M 6 x 1 .0 x 4 5 ( 2 )

(5 2 )

–

S e a l, F a c e ( 3 )

(8 ) (9 )

– –

H a r n e s s A s s e m b l y , C o n t r o l, I n t e r n a l C o n n e c t o r A s s e m b ly

(5 3 ) (5 4 )

– –

S p r in g , A c c u m u la t o r ( 2 ) P lu g , A c c u m u la t o r ( 2 )

C o n n e c t o r

(5 5 )

–

P lu g , A c c u m u la t o r ( 2 )

S e a l

(5 6 )

–

S p r in g , A c c u m u la t o r ( 2 )

(5 7 ) (5 8 )

– –

S w it c h A s s e m b ly S w it c h

(5 9 )

–

B r a c k e t

(1 0 ) (1 1 )

– –

(1 2 )

–

S e a lr in g

(1 3 ) (1 4 )

– –

S t a n d o f f , W ir in g H a r n e s s G r o m m e t

(1 5 )

–

B o lt , 2 0 F C o n n e c t o r

(6 0 )

–

B o lt , M 6 x 1 .0 x 9 5 ( 1 2 )

(1 6 ) (1 7 )

– –

S e n s o r , T e m p e r a t u r e ( O I L T ) C o n n e c t o r A s s e m b ly ( T E M P )

(6 1 )

–

B o d y A s s e m b ly , S o le n o id

(1 8 )

–

C o n n e c t o r, 2 W a y

(6 2 ) (6 3 )

– –

B o d y A s s e m b ly , S o l e n o id V a l v e A n d P i n B o d y

(1 9 )

–

T e r m in a l, S o c k e t

(6 4 )

–

P in ( 3 )

(2 0 )

–


(6 5 )

–

(2 1 ) (2 2 )

– –

L o c k , S e c o n d a r y C o n n e c t o r A s s e m b ly ( S S 1 )

S o l e n o i d , T C C , V a r ia b l e B le e d , C E N L . C o n n e c t o r B o d y

(6 6 )

–

O - r in g , 1 3 .0 m m

I D

(2 3 )

–


(6 7 )

–

O - r in g , 1 0 .5 m m

I D

(2 4 ) (2 5 )

– –

T e r m in a l, S o c k e t C o n n e c t o r, 2 W a y

(6 8 ) (6 9 )

– –

V a lv e , L o c k u p T r im S p r in g

(2 6 )

–

C h a n n e l

(7 0 )

–

(2 7 )

–

O il L e v e l S e n s o r

S o l e n o id , P C S 1 , V a r i a b le B l e e d , C E N H . C o n n e c to r B o d y

(2 8 )

–

C o n n e c t o r , P lu g , 3 - W a y

(2 9 ) (3 0 )

– –

T e r m in a l, S o c k e t L o c k , S e c o n d a r y

(7 1 ) (7 2 )

– –

O - r in g , 1 3 .0 m m O - r in g , 1 0 .5 m m

(7 3 )

–

V a l v e , C lu t c h T r im

(3 1 )

–


(3 2 )

–


(7 4 ) (7 5 )

– –

(3 3 )

–

C o n n e c t o r A s s e m b ly , 2 - W a y S p e e d S e n s o r ( N T 1 )

(7 6 )

–

S S C O

(3 4 )

–


(3 5 ) (3 6 )

– –

T e r m in a l, S o c k e t C o n n e c t o r

(7 7 ) (7 8 )

– –

O - r in g , 1 0 . 5 m m I D V a l v e , C lu t c h T r im

(7 9 )

–

S p r in g , T r im

(3 7 )

–

C o n n e c to r A s s e m b ly , 2 - W a y ( M a in M o d u la t o r )

(3 8 )

–

– –

C lip V a l v e , D ia g n o s t ic ( 3 )

(8 2 )

–

S p r in g , D ia g n o s t ic ( 3 )

(3 9 )

–

C o n n e c t o r A s s e m b ly , 2 - W a y S p e e d S e n s o r ( N T 1 ) T e r m in a l, S o c k e t

(8 0 ) (8 1 ) (8 3 )

–

(4 0 )

–


(4 1 )

–

C o n n e c t o r

(8 4 )

–

S o l e n o id , P C S 3 , V a r i a b le B l e e d , C E N L . C o n n e c to r B o d y O - r in g , 1 3 . 0 m m I D

(4 2 )

–

C o n n e c to r A s s e m b ly , 2 - W a y P r e s s u r e S w it c h ( P S 1 )

(8 5 )

–

O - r in g , 1 0 .5 m m

(4 3 ) (4 4 )

– –

T e r m in a l, S o c k e t T e r m in a l, S o c k e t

(8 6 ) (8 7 )

– –

V a l v e , C lu t c h T r im S p r in g , T r im

F o l d o u t 1 6

C o p y r ig h t ©

I D I D

p r in g , T r im o l e n o id , P C S 2 , V a r i a b le B l e e d , C E N H . o n n e c to r B o d y - r in g , 1 3 . 0 m m I D


I D


S E R V IC E

(8 8 )

–

S o le n o id , P C S 4 , V a r i a b le B le e d , C E N L . C o n n e c to r B o d y ID

(1 2 7 ) –

V a l v e , E x h a u s t B a c k

(1 2 8 ) – (1 2 9 ) –

S p r in g , E x h a u s t B a c k S t o p , E x h a u s t B a c k

(1 3 0 ) –

P in , R e te n tio n , 5 O D

(1 3 1 ) – (1 3 2 ) –

V a l v e , C 1 L a t c h S p r in g , C 1 L a t c h

(8 9 )

–

O - r in g , 1 3 .0 m m

(9 0 ) (9 1 )

– –

O - r in g , 1 0 .5 m m ID V a l v e , C lu t c h T r im

(9 2 )

–

S p r in g , T r im

(9 3 )

–

(1 3 3 ) –

S t o p , C 1 L a tc h

(1 3 4 ) –

P in , R e te n tio n , 3 O D

(9 4 )

–

S o le n o id , M a in M o d , V a r i a b le B l e e d , C E N L . C o n n e c t o r O - r in g , 1 3 .0 m m ID

(1 3 5 ) –

V a l v e , C o n v e r t e r R e g u la t o r

(9 5 )

–

O - r in g , 1 0 .5 m m

(9 6 )

–

B o lt , M 6 x 1 .0 x 2 0 ( 2 )

(1 3 6 ) – (1 3 7 ) –

S p r in g , C o n v e r t e r R e g u la t o r S t o p , C o n v e r t e r R e g u l a t o r

(9 7 )

–

S e n s o r, S p e e d

(1 3 8 ) –

B o lt, M 6 x 1 .0 x 4 5 ( 2 )

(9 8 ) (9 9 )

– –

B o lt , M 6 x 1 .0 x 6 0 ( 2 ) P la t e , S o le n o i d S e p a r a t o r

(1 3 9 ) – (1 4 0 ) –

S e n s o r A s s e m b ly , O il L e v e l F e r r u l e , V i t o n ® ( 2 )

(1 0 0 ) –

B o d y A s s e m b ly , M a in V a lv e

(1 4 1 ) –

P la t e , S e p a r a t o r

(1 0 1 ) – (1 0 2 ) –

P in , R e t e n tio n , 5 O D V a l v e , L o c k u p

(1 4 2 ) –

G a s k e t, C h a n n e l P la t e

(1 4 3 ) –

P la t e A s s e m b ly , C h a n n e l

(1 0 3 ) –

S p r in g , L o c k u p

(1 0 4 ) –

S t o p , L o c k u p

(1 4 4 ) – (1 4 5 ) –

P in , D o w e l, 1 0 x 5 0 m m P la t e , O i l T r a n s f e r

(1 0 5 ) –

P in , R e t e n tio n , 3 O D

(1 0 6 ) – (1 0 7 ) –

V a l v e , L u b e R e g u l a t o r S p r in g , L u b e R e g u l a t o r

(1 4 6 ) – (1 4 7 ) –

P lu g A s s e m b l y , O il D r a in O - r in g , 1 6 .4 m m I D

(1 0 8 ) –

S t o p , L u b e R e g u la t o r

(1 4 8 ) – (1 4 9 ) –

P lu g A s s e m b ly , P r e s s u r e T a p ( 1 0 ) O - r in g , 8 . 9 m m I D

(1 0 9 ) – (1 1 0 ) –

P i n , R e t e n tio n , 5 O D x 4 3 m m V a l v e , M a in R e g u l a t o r

(1 5 0 ) – (1 5 1 ) –

P lu g , P r e s s u r e T a p F i l t e r , O i l ( 2 )

(1 1 1 ) –

S p r in g , M a in R e g u l a t o r

(1 5 2 ) –

O - r in g , 7 5 .9 m m

ID

( 2 )

(1 1 2 ) –

S t o p , M a in R e g u la t o r

(1 5 3 ) –

O - r in g , 8 5 .3 m m

ID

( 2 )

(1 1 3 ) –

V a lv e , C o n t r o l M a i n

(1 5 4 ) –

G a s k e t , F i lt e r C o v e r ( 2 )

(1 1 4 ) – (1 1 5 ) –

S p r in g , C o n t r o l M a i n C li p , C o n t r o l M a i n

(1 5 5 ) – (1 5 6 ) –

C o v e r , F i lt e r ( 2 ) B o lt, M 6 x 1 .0 x 4 5 ( 4 )

(1 1 6 ) –

P in , R e te n tio n , 2 .5 O D

(1 5 7 ) –

P r e s s u r e S w it c h

(1 1 7 ) –

S o le n o id A s s e m b ly

(1 1 8 ) – (1 1 9 ) –

O - r in g , 1 8 .8 m m O - r in g , 1 4 .0 m m

(1 5 8 ) – (1 5 9 ) –

B o d y A s s e m b l y , F i lt e r L i f e V a l v e B o d y , F i l t e r L i f e

(1 6 0 ) –

V a l v e , F i l t e r L i f e

(1 2 0 ) –

B o d y , C o n t r o l V a l v e

(1 6 1 ) –

S p r i n g , F i l t e r L i f e

(1 2 1 ) – (1 2 2 ) –

P in , S p r in g P in , R e t e n tio n , 5 O D

(1 6 2 ) –

P lu g

(1 2 3 ) –

V a l v e , C 2 L a t c h

(1 6 3 ) – (1 6 4 ) –

C lip B o lt, M 1 0 x 1 .5 x 1 0 0 ( 2 5 )

(1 2 4 ) –

S p r in g , C 2 L a t c h

(1 6 5 ) –

B o lt, M 1 0 x 1 .5 x 5 5 ( 7 )

(1 2 5 ) –

S t o p , C 2 L a tc h

(1 6 6 ) –

G a s k e t , C a s e

(1 2 6 ) –

P in , R e t e n tio n , 5 O D

ID

x 4 3 m m

x 4 3 m m

x 4 0 m m

I D I D

x 4 3 m m

x 4 3 m m

x 4 3 m m

( 2 )

x 4 3 m m

C o p y r ig h t ©

2 0 0 9


F o ld o u t 1 6

S E R V IC E

F o l d o u t 1 6


C o p y r ig h t ©


F O L D O U T 1 6

F o ld o u t 1 6 -1 . C o n tr o l V a lv e M o d u le w ith

P ro g n o s tic s —

D i s a s s e m b le d V i e w

F o ld o u t 1 6 -2 . C o n tr o l V a lv e M o d u le w ith P ro g n o s tic s —

D i s a s s e m b le d V ie w

S E R V IC E



C o p y r ig h t ©

2 0 0 9



F o ld o u t 1 7

S E R V IC E


L e g e n d


1 7 - 1

1 7 - 2

(1 )

–

O u tp u t fl a n g e

(1 )

–

P 3 c a r r i e r a s s e m b ly

(2 ) (3 )

– –

B la n k fl a n g e O - r in g

(2 ) (3 )

– –

I n t e r n a l r e t a i n i n g r in g P 3 in d e x in g r in g

(4 )

–

O - r in g

(4 )

–

C a r r ie r a n d b u s h in g a s s e m b ly

(5 )

–

O - r in g

(5 )

–

P 3 p la n e ta r y c a r r ie r

(6 ) (7 )

– –

R e t a in e r p l u g B o l t , M 1 0 x 1 . 5 x 3 0 ( 2 ) , A

(6 ) (7 )

– –

B u s h in g P 3 p la n e t a r y s p in d le ( 4 )

(8 ) (9 )

– –

O u t p u t s h ip p in g c o v e r O u tp u t y o k e

(8 ) (9 )

– –

P 3 th ru s t w a s h e r ( 4 ) P 3 p in io n g e a r s e t ( c o n ta in s 4 p in io n s )

O u tp u t y o k e

(1 0 )

B o lt

(1 1 )

S lin g e r

(1 2 )

–

S e l e c t iv e s h im

(1 3 ) (1 4 )

– –

A d a p t e r h o u s in g g a s k e t A d a p t e r h o u s in g a s s e m b l y

(1 5 )

–

E x t e r n a l r e t a i n i n g r in g

(1 6 ) (1 7 )

– –

S p r in g r e t a in e r a s s e m b ly C 5 c lu t c h p is to n

(1 8 )

–

C 5 o u t e r p is t o n s e a lr in g

(1 9 )

–

C 5 in n e r p is t o n s e a lr in g

(2 0 )

–

A d a p t e r h o u s in g

(2 1 ) (2 2 )

– –

P l u g a s s e m b ly P l u g , A

(2 3 )

–

O - r in g

(2 4 ) (2 5 )

– –

F i lt e r s c r e e n B o l t , M 1 0 x 1 . 5 x 7 0 ( 4 ) , B

(2 6 )

–

T r a n s f e r c a s e h o u s in g g a s k e t

(2 7 )

–

(2 8 )

–

B o l t , M 1 0 x 1 .5 x 2 0 5 , ( s t e p p e d a n d k n u r le d s h a n k ) B B B o l t , M 1 0 x 1 . 5 x 2 0 5 , ( b u l g e d s h a n k ) B

(2 9 )

–

B o l t , M 1 2 x 1 . 7 5 x 6 0 ( 3 ) , C

(3 0 )

–

B o l t , M 1 0 x 1 . 5 x 1 0 0 ( 3 ) , B

(3 1 ) (3 2 )

– –

B o l t , M 1 0 x 1 . 5 x 4 0 ( 2 ) , B B o l t , M 1 2 x 1 . 7 x 4 5 ( 1 5 ) , C

(3 3 )

–

B o l t , M 1 0 x 1 . 5 x 4 0 ( 1 9 ) , B

(1 0 ) (1 1 ) (1 2 )

– – –

T o rq u e

N ∙m

lb

ft

A

3 0 – 3 5

2 2 – 2 6

B

7 0 – 8 0

5 1 – 6 0

– –

R o lle r b e a r in g a s s e m b ly ( 8 ) P 3 t h r u s t w a s h e r ( 4 )

T o rq u e

F o l d o u t 1 7

C o p y r ig h t ©

N ∙m

lb

f t

A

3 4 – 4 7

2 5 – 3 5

B

5 1 – 6 1

3 8 – 4 5

C

9 0 – 1 1 0

6 6 – 8 1


F O L D O U T 1 7

F o ld o u t 1 7 -1 . O u tp u t F la n g e a n d

Y o k e —


V ie w

F o ld o u t 1 7 -2 . T r a n s fe r C a s e A d a p te r H o u s in g —

D is a s s e m b l e d V i e w

S E R V IC E



C o p y r ig h t ©

2 0 0 9



F o ld o u t 1 8


S E R V IC E

L e g e n d


1 8 - 1

1 8 - 2

(1 )

–

G a s k e t

(1 )

–

B o l t , M 1 0 x 1 . 5 x 6 0 ( 1 6 ) , B

(2 ) (3 )

– –

C o v e r C o o le r p o r t m a n if o ld

(2 ) (3 )

– –

A d a p te r G a s k e t , m a n if o ld t o W a t e r

(4 )

–

B o l t , M 1 0 x 1 . 5 x 2 8 ( 6 ) , A

(4 )

–

G a s k e t , i n t e g r a l c o o le r

(5 )

–

G a s k e t ( w it h o u t r e t a r d e r )

(5 )

–

B o l t , M 8 x 1 . 2 5 x 2 5 ( 6 ) , A

(6 ) (7 )

– –

G a s k e t ( r e t a r d e r ) C o o le r h o u s in g

(6 ) (7 )

– –

G a s k e t , m a n i f o l d t o c o o le r , ( 2 ) C o o le r , i n t e g r a l

(8 ) (9 )

– –

G a s k e t (2 ) C o n n e c to r (2 )

(8 ) (9 )

– –

B o l t , M 1 2 x 1 . 7 5 x 2 1 8 ( 3 ) , C B o l t , M 1 0 x 1 . 5 x 2 1 0 ( 8 ) , B

B o l t , M 1 0 x 1 . 5 x 3 5 ( 8 ) , A

(1 0 )

W a s h e r

(1 1 )

(1 0 ) (1 1 )

– –

– –

M a n i f o l d a s s e m b l y , i n t e g r a l c o o l e r P lu g a s s e m b ly , s h ip p in g , S A E

(1 2 )

–

B o l t , M 1 0 x 1 . 5 x 2 0 5 ( u s e d w i t h r e t a r d e r ) , A

(1 2 )

–

S h ip p in g p lu g

(1 3 ) (1 4 )

– –

B o l t , M 1 2 x 1 . 7 5 x 2 3 0 ( 3 , w i t h r e t a r d e r ) , B W a s h e r ( 3 )

(1 3 ) (1 4 )

– –

O - r in g P lu g a s s e m b ly , p r e s s u r e t a p

(1 5 )

–

B o l t , M 1 0 x 1 . 5 x 7 0 ( 9 , w i t h o u t r e t a r d e r ) , A

(1 5 )

–

O - r in g , 1 1 .6 m m

(1 5 ) (1 6 )

– –

B o l t , M 1 0 x 1 . 5 x 2 2 5 ( 6 , w i t h r e t a r d e r ) , A W a s h e r ( 9 , o r 6 )

(1 6 ) (1 7 )

– –

M a n i f o l d , i n t e g r a l , s t r a p p e d P lu g a s s e m b ly , p r e s s u r e t a p

(1 7 )

–

P r e s s u r e t a p p l u g a s s e m b l y ( 2 ) , C

(1 8 )

–

P lu g , p r e s s u r e t a p

(1 8 )

–

P r e s s u r e t a p p lu g

(1 9 )

–

O - r in g , 8 .9 m m

(1 9 )

–

O - r in g

(2 0 )

–

P lu g a s s e m b ly , p r e s s u r e t a p

(2 0 ) (2 1 )

– –

P l u g , 1 / 2 - 1 4 , D E lb o w ( 2 )

(2 1 ) (2 2 )

– –

P lu g , p r e s s u r e t a p O - r in g , 8 . 9 m m ID

(2 2 )

–

G a s k e t

(2 3 )

–

P lu g a s s e m b ly , p r e s s u r e t a p

(2 3 ) (2 4 )

– –

C o v e r B o l t , M 1 2 x 1 . 7 5 x 2 5 ( 2 ) , E

(2 4 ) (2 5 )

– –

O - r in g , 9 . 3 m m ID P lu g a s s e m b ly , p r e s s u r e t a p

(2 5 )

–

B o l t , M 1 0 x 1 . 5 x 3 5 ( 1 7 ) , A

(2 6 )

–

P lu g , p r e s s u r e t a p

(2 6 )

–

O - r in g ( 2 )

(2 7 )

–

O - r in g , 8 .9 m m

(2 7 )

–

P la t e a s s e m b ly

(2 8 ) (2 9 )

– –

O - r in g O - r in g T o rq u e

T o rq u e

N ∙m

lb

ft

A

5 1 – 6 1

3 8 – 4 5

B

1 0 0 – 1 2 0

7 4 – 8 8

C

1 0 – 1 3

7 – 1 0

D

2 2 – 2 7

1 6 – 2 0

E

9 0 – 1 1 0

6 6 – 8 1

F o l d o u t 1 8

C o p y r ig h t ©

N o . 1 6

I D

ID

ID N ∙m

lb

f t

A

3 3

2 4

B

6 3

4 7

C

1 1 3

7 9


F O L D O U T 1 8

F o ld o u t 1 8 -1 . O il C o o le r — D is a s s e m b le d V ie w

F o l d o u t 1 8 - 2 . I n t e g r a l S u m p C o o l e r — D is a s s e m b l e d V i e w

S E R V IC E



C o p y r ig h t ©

2 0 0 9



F o ld o u t 1 9


S E R V IC E

L e g e n d


1 9 - 1 (1 )

–

S c a v e n g e p u m p m o d u le

(2 ) (3 )

– –

P in P u m p h o u s in g

(4 )

–

S h a ft

(5 )

–

O - r in g , 1 2 .4 m m

(6 ) (7 )

– –

O - r in g , 1 2 .4 m m ( 0 . 4 8 8 in c h ) I D B o l t , M 8 x 1 . 2 5 x 3 0 ( 3 ) , A

(8 ) (9 )

– –

D r i v e n g e a r a s s e m b ly R o lle r b e a r in g a s s e m b ly

(1 0 )

–

(1 1 )

–

( 0 . 4 8 8 in c h ) I D

R o lle r b e a r in g a s s e m b ly D r iv e n g e a r

(1 2 )

–

T h r u s t w a s h e r

(1 3 ) (1 4 )

– –

P u m p a s s e m b ly P u m p c o v e r

(1 5 )

–

G e a r s e t

(1 6 ) (1 7 )

– –

T h r u s t w a s h e r P u m p b o d y

(1 8 )

–

G a s k e t

(1 9 )

–

B o l t , M 8 x 1 . 2 5 x 2 0 ( 3 ) , A T o rq u e

N ∙m

A

3 0 – 3 5

lb

f t

2 3 – 2 5

1 9 - 2 (1 )

–

P a r k in g b ra k e , 1 2 x 4

(2 )

–

B o l t , M 1 6 x 2 . 0 x 4 0 ( 4 ) , A

(3 ) (4 )

– –

B r a k e d r u m B o l t , 3 ∕8∕8 - 2 4 x 3 ∕4∕4 ( 2 ) , B

(5 )

–

S tu d ( 2 )

(6 ) (7 )

– –

P T O g a s k e t B o l t , M 1 0 x 1 . 5 x 3 5 ( 8 ) , C

(8 )

–

P T O

(9 )

–

S tu d ( 2 )

(1 0 ) (1 1 ) (1 2 )

a s s e m b ly

–

P T O

–

B o l t , M 1 0 x 1 . 5 x 3 5 ( 8 ) , C P T O a s s e m b ly

–

T o rq u e

g a s k e t

N ∙m

lb

f t

A

2 2 8 – 2 6 6

B

5 6 – 6 6

4 1 – 4 9

C

5 1 – 6 1

3 8 – 4 5

F o l d o u t 1 9

1 6 8 – 1 9 6

C o p y r ig h t ©


F O L D O U T 1 9

F o l d o u t 1 9 - 1 . S c a v e n g e P u m p — D is a s s e m b l e d V i e w

F o ld o u t 1 9 -2 . S u p p o r t E q u ip m e n t— D is a s s e m b le d V ie w

F O L D O U T 2 0

F o ld o u t 2 0

. 3 0 0 0 P r o d u c t F a m ily

H y d r a u lic

S c h e m a tic —

N e u t r a l

F O L D O U T 2 1

F o ld o u t 2 1 . 3 0 0 0 P r o d u c t F a m ily

H y d r a u li c

S c h e m a tic —

R e v e r s e

F O L D O U T 2 2


H y d r a u lic

S c h e m a tic —

7 -S p e e d , L o w

R a n g e

F O L D O U T 2 3


H y d r a u li c

S c h e m a tic —

F i r s t R a n g e

F O L D O U T 2 4

F o ld o u t 2 4

. 3 0 0 0 P r o d u c t F a m ily

H y d r a u lic

S c h e m a tic —

S e c o n d

R a n g e

F O L D O U T 2 5


H y d r a u lic

S c h e m a tic —

T h ir d

R a n g e

F O L D O U T 2 6


H y d r a u lic

S c h e m a tic —

F o u r th

R a n g e

F O L D O U T 2 7


H y d r a u li c

S c h e m a tic —

F ifth

R a n g e

F O L D O U T 2 8


H y d r a u lic

S c h e m a tic —

S ix th

R a n g e

F O L D O U T 2 9


H y d r a u lic

S c h e m a tic —

R e t a r d e r O F F

F O L D O U T 3 0


H y d r a u lic

S c h e m a tic —

R e t a r d e r O N

F O L D O U T 3 1

F o l d o u t 3 1 . 3 0 0 0 P r o d u c t F a m ily

H y d r a u lic

S c h e m

a tic —

N e u tr a l W

ith


F O L D O U T 3 2


H y d r a u lic

S c h e m a tic —

R e v e r s e R a n g e

W ith


F O L D O U T 3 3

F o ld o u t 3 3

. 3 0 0 0 P r o d u c t F a m ily

H y d r a u lic

S c h e m

a t ic —

F ir s t R a n g e

W ith


F O L D O U T 3 4


H y d r a u lic

S c h e m a tic —

S e c o n d

R a n g e

W ith

P r o g n o s tic s

F O L D O U T 3 5


H y d r a u lic

S c h e m a tic —

T h ir d

R a n g e

W

ith

P r o g n o s tic s

F O L D O U T 3 6


H y d r a u lic

S c h e m a tic —

F o u r th

R a n g e

W ith

P r o g n o s ti c s

F O L D O U T 3 7

F o ld o u t 3 7

. 3 0 0 0 P r o d u c t F a m ily

H y d r a u lic

S c h e m

a t ic —

F ifth

R a n g e

W ith


F O L D O U T 3 8


H y d r a u lic

S c h e m a tic —

S ix th

R a n g e

W ith

P r o g n o s tic s

SM4013EN 200906

Printed in USA 200907

3K Service Manual 4th Gen SM4013EN 200906

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