Allison 4th Generation Service Manual PDF 4000 4500 4700 4800 Transmission – PDF

Description

Allison 4th Generation Service Manual PDF 4000 4500 4700 4800 Transmission SM4014EN – PDF DOWNLOAD

DESCRIPTION

This is the official Allison Transmission 4th Generation Controls Service Manual (Document Number SM4014EN, Published October 2005, Copyright © 2005 General Motors Corporation). This comprehensive 174-page technical manual is intended for qualified transmission service technicians and provides complete maintenance, troubleshooting, repair, and overhaul procedures for Allison 4th Generation vocational automatic transmissions used in heavy-duty trucks, buses, fire apparatus, refuse vehicles, and specialty equipment worldwide.

Product Overview

Allison 4th Generation Controls – Vocational Models:

The Allison 4th Generation represents General Motors’ advanced fully automatic transmission platform designed for demanding vocational applications. These sophisticated transmissions combine electronic control, hydraulic actuation, planetary gearsets, and torque converter technology to deliver reliable power transfer, smooth shifting, and exceptional durability for heavy-duty commercial vehicles operating in severe-duty applications.

Key Applications:

• Heavy-duty trucks
• Refuse collection vehicles
• Fire apparatus and emergency vehicles
• Transit buses
• Motor coaches
• Construction equipment
• Utility vehicles
• Delivery trucks
• Specialty vocational vehicles
• Municipal fleet operations

Models Covered

4000 Series Models:

• 4000 EVS – Enhanced Vehicle Specification
• 4000 HS – Highway Series
• 4000 MH – Motor Home
• 4000 RDS – Rugged Duty Series
• 4000 SP – Special Performance
• 4000 TRV – Transit/RV

Dry Weights (4000 Series):

• Base transmission: 377 kg (831 lbs)
• With PTO provision: 405 kg (893 lbs)
• With retarder: 411 kg (906 lbs)
• With retarder and PTO: 439 kg (968 lbs)

4500 Series Models:

• 4500 EVS – Enhanced Vehicle Specification
• 4500 HS – Highway Series
• 4500 RDS – Rugged Duty Series
• 4500 SP – Special Performance

Dry Weights (4500 Series):

• Base transmission: 377 kg (831 lbs)
• With PTO provision: 405 kg (893 lbs)
• With retarder: 411 kg (906 lbs)
• With retarder and PTO: 439 kg (968 lbs)

4700 Series Models:

• 4700 EVS – Enhanced Vehicle Specification
• 4700 RDS – Rugged Duty Series
• 4700 SP – Special Performance

Dry Weights (4700 Series):

• Base transmission: 493 kg (1087 lbs)
• With PTO provision: 521 kg (1149 lbs)
• With retarder: 529 kg (1162 lbs)
• With retarder and PTO: 555 kg (1224 lbs)
• With retarder, PTO, and integral retarder sump cooler: 496 kg (1032 lbs)

4800 Series Models:

• 4800 EVS – Enhanced Vehicle Specification
• 4800 SP – Special Performance

Dry Weights (4800 Series):

• Base transmission: 493 kg (1087 lbs)
• With PTO provision: 521 kg (1149 lbs)
• With retarder: 529 kg (1162 lbs)
• With retarder and PTO: 555 kg (1224 lbs)

Torque Converter Models:

• B 500 – Base torque converter
• T 425 – Torque converter variant
• T 450 – Torque converter variant
• T 525 – Torque converter variant

Key Technical Systems

Electronic Control:

• Electronic Control Unit (ECU)
• Allison DOC™ (Diagnostic Optimized Connection Tool)
• 4th Generation electronic controls
• Shift selector with digital display
• Diagnostic data reader/tool interfaces
• Prognostics capabilities

Transmission Components:

• Planetary gearsets
• Hydraulic clutch packs
• Torque converter assembly
• Main control module
• Valve body and hydraulics
• Output shaft and bearing assemblies
• PTO provisions (optional)

Optional Features:

• Retarder module (integral hydraulic retarder)
• PTO (Power Take-Off) provisions
• Integral retarder sump cooler
• C6 adapter housing module

Shift Ranges:

• D (Drive)
• N (Neutral)
• R (Reverse)
• Additional mode selections
• Manual shift control capability

Comprehensive Manual Contents

DOCUMENT INFORMATION:

• Document Number: SM4014EN
• Title: Allison 4th Generation Controls Vocational Models Service Manual
• Published: October 2005
• Copyright: © 2005 General Motors Corporation
• Manufacturer: Allison Transmission, General Motors Corporation
• Address: P.O. Box 894, Indianapolis, Indiana 46206-0894
• Pages: 174 pages
• Format: Letter size (612 x 792 pts)
• Creator: FrameMaker 7.0
• PDF Version: 1.6
• PDF Subtype: PDF/X-3:2002 (ISO 15930-3)
• File Size: 19.6 MB

INTRODUCTION AND CONVENTIONS

Electronic Control Unit and Diagnostic Data Reader/Tool:

• Display and button name conventions
• Bold capital letters for controls (↑, ↓, MODE, MONITOR, SELECT)
• Transmission range shifts indicated (D (Drive), N (Neutral), etc.)
• Diagnostic messages in double quotation marks (“OL,” “OK,” etc.)

Trademark Usage:

• Allison DOC™ – Allison Diagnostic Optimized Connection Tool (General Motors Corp.)
• DEXRON® – Registered trademark of General Motors Corp.
• Biobor® JF – Biological inhibitor (U.S. Borax and Chemical Corporation)
• Loctite® – Registered trademark of Loctite Corporation
• Teflon® – Registered trademark of DuPont Corporation
• TranSynd™ – Trademark of Castrol, Ltd.
• Vespel® – Registered trademark of DuPont Corporation

Publication Notes:

• Periodically revised for improvements and new models
• Check with Allison service outlet for current publication
• Additional copies available from authorized service outlets
• Look under Transmissions—Truck, Tractor, etc. in telephone directory

IMPORTANT SAFETY NOTICE

Responsibility Statement:

• Complete familiarity with Warnings and Cautions required
• Warnings and Cautions advise against unsafe service methods
• Can result in personal injury or equipment damage
• Warnings and Cautions are not exhaustive
• Allison has not evaluated all conceivable service methods
• ANYONE USING NON-RECOMMENDED PROCEDURES must ensure safety
• Use special tools when and as recommended

Safety Heading Types:

⚠ WARNING!

• Operating procedure that if not correctly followed could result in personal injury or loss of life

⚠ CAUTION:

• Operating procedure that if not strictly observed could result in damage to or destruction of equipment

NOTE:

• Operating procedure, practice, etc., that is essential to highlight

LIST OF WARNINGS (Your Responsibility to Know All)

Vehicle Movement Warnings:

• If leaving vehicle with engine running, vehicle can move suddenly
• Put transmission in N (Neutral)
• Apply parking brake and emergency brakes
• Chock wheels
• Take steps to prevent vehicle movement

Hot Fluid and Component Warnings:

• Avoid contact with hot fluid or hot sump when draining
• Direct contact may result in bodily injury

Converter Stall Test Warning:

• DO NOT conduct until:
  • Parking brake/emergency brakes set and engaged
  • Wheels chocked
  • Personnel warned to keep clear
  • Failure can cause serious injury

Safety Equipment:

• Use appropriate safety equipment
• Safety glasses, safety shoes, gloves required

Material Handling:

• Do not burn discarded Teflon® seals – toxic gases produced
• Never dry bearings by spinning with compressed air
• Spinning bearing can disintegrate – flying projectiles
• Spinning without lubrication damages bearing

Hydraulic System:

• DO NOT disconnect hydraulic line between accumulator and retarder
• Must bleed air and hydraulic pressure first

Lifting and Weight Warnings:

PREVENT PERSONAL INJURY:

• Use proper tools and lifting equipment
• Transmission dry weights specified for all models
• Get help when lifting heavy modules:
  • Control module: ~25 kg (55 lb)
  • Retarder module: ~34 kg (75 lb)
  • C6 adapter housing module: ~68 kg (150 lb)

Spring Force Warnings:

• Carefully release spring force
• Piston springs highly compressed
• Personal injury can occur if not controlled
• Be extremely careful during removal/installation

Planetary Assembly:

• Place P3 planetary assembly on its side
• Avoid possible injury while disassembling

TYPICAL MANUAL SECTIONS

Based on standard Allison service manual structure:

Section 1: General Information

• Transmission identification
• Model specifications
• Application information
• Fluid specifications
• Torque converter specifications

Section 2: Electronic Controls

• 4th Generation control system
• ECU operation
• Shift selector operation
• Diagnostic capabilities
• Allison DOC™ tool operation

Section 3: Diagnostics and Troubleshooting

• Diagnostic trouble codes
• Allison DOC™ procedures
• Systematic troubleshooting
• Hydraulic system diagnosis
• Electronic system diagnosis

Section 4: On-Vehicle Service

• Fluid and filter service
• External component replacement
• Adjustment procedures
• Leak diagnosis and repair

Section 5: Removal and Installation

• Transmission removal procedures
• Installation procedures
• Alignment procedures
• Linkage adjustments

Section 6: Disassembly

• Complete transmission disassembly
• Component removal sequences
• Special tool usage
• Subassembly disassembly

Section 7: Inspection and Cleaning

• Component inspection procedures
• Wear limits and specifications
• Cleaning methods
• Component testing

Section 8: Assembly

• Subassembly assembly procedures
• Complete transmission assembly
• Torque specifications
• Clearance checks
• Special tool procedures

Section 9: Testing and Adjustments

• Converter stall test
• Pressure tests
• Output shaft endplay
• Final adjustments

Section 10: Hydraulic Schematics

• Hydraulic circuit diagrams
• Component locations
• Oil flow paths
• Pressure specifications

Section 11: Special Tools

• Special tool listings
• Tool part numbers
• Tool usage procedures

Who Needs This Manual?

This Allison 4th Generation service manual is essential for:

• Allison authorized transmission service centers
• Heavy-duty truck repair facilities
• Fleet maintenance operations
• Transmission rebuild specialists
• Vocational vehicle maintenance teams
• Fire apparatus technicians
• Transit authority maintenance departments
• Anyone performing authorized service on Allison 4th Gen transmissions

Prerequisites:

✓ Qualified transmission service personnel only
✓ Heavy-duty automatic transmission experience
✓ Understanding of electronic control systems
✓ Allison DOC™ diagnostic tool training
✓ Proper special tools and lifting equipment
✓ Hydraulic system knowledge
✓ Torque wrench proficiency
✓ Safety training for heavy equipment

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