Allison Transmission 3000 & 4000 Product Families 4th Generation Controls Mechanic’s Tips Manual – PDF DOWNLOAD

Description

Allison Transmission 3000 & 4000 Product Families 4th Generation Controls Mechanic’s Tips Manual – PDF DOWNLOAD

DESCRIPTION:

Allison Transmission 3000 & 4000 Product Families 4th Generation Controls Mechanic’s Tips Manual – PDF DOWNLOAD

ABOUT THIS MANUAL:

• This manual is a mechanic’s reference for maintaining, removing, or installing
  3000 and 4000 Product Family transmissions with Allison 4th Generation Controls.
  All features of the transmission and the vehicle involved in installation procedures
  are discussed.
• The information presented will help the mechanic maintain, remove,
  or install the transmission in a manner that assures satisfactory operation and long
  service life.
• For additional detailed information, refer to the appropriate
  transmission service manual and electronic controls troubleshooting manual.
  Unless specifically indicated otherwise, this manual refers to all Allison 4th
  Generation Controls for 3000 and 4000 Product Family transmissions, except for
  the 3700 SP model.
• The differences between the various transmission models are
  explained as required.

TABLE OF CONTENTS:

Allison Transmission 3000 & 4000 Product Families 4th Generation Controls Mechanic’s Tips Manual – PDF DOWNLOAD

SECTION I INTRODUCTION
1–1 ABOUT THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
SECTION II PREVENTIVE MAINTENANCE
2–1 PERIODIC INSPECTION AND CARE . . . . . . . . . . . . . . . . . . . . . . 18
2–2 IMPORTANCE OF PROPER TRANSMISSION FLUID LEVEL . . . . . . . 19
2–3 TRANSMISSION FLUID CHECK . . . . . . . . . . . . . . . . . . . . . . . . . 19
2–4 KEEPING FLUID CLEAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2–5 FLUID RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2–6 TRANSMISSION FLUID AND FILTER CHANGE INTERVALS . . . . . . 26
2–7 TRANSMISSION FLUID CONTAMINATION . . . . . . . . . . . . . . . . . . 30
2–8 TRANSMISSION FLUID AND FILTER CHANGE PROCEDURE . . . . . 31
2–9 FLUID LEAK DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2–10 BREATHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2–11 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2–12 TRANSMISSION STALL TEST . . . . . . . . . . . . . . . . . . . . . . . . . . 42
SECTION III REMOVING TRANSMISSION
3–1 DRAINING TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
3–2 DISCONNECTING CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . 47
3–3 UNCOUPLING FROM DRIVELINE, ENGINE, AND VEHICLE . . . . . . 49
3–4 REMOVING THE TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . 50
3–5 REMOVING OUTPUT FLANGE OR YOKE . . . . . . . . . . . . . . . . . . . 50
SECTION IV TRANSMISSION PREPARATION
4–1 CHECKING INPUT COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . 51
4–2 INSTALLING OUTPUT FLANGE OR YOKE . . . . . . . . . . . . . . . . . . 51
4–3 INSTALLING PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
4–4 INSTALLING FILL TUBEAND SEAL . . . . . . . . . . . . . . . . . . . . . . 52
4–5 CHECKING PLUGSAND OPENINGS . . . . . . . . . . . . . . . . . . . . . . 53
SECTION V PREPARING VEHICLE FOR TRANSMISSION
INSTALLATION
5–1 ENGINE, TRANSMISSION ADAPTATION REQUIREMENTS . . . . . . . 54
5–2 CHECKING FLEXPLATE DRIVE ASSEMBLY . . . . . . . . . . . . . . . . . 57
5–3 CHASSIS AND DRIVELINE INSPECTION . . . . . . . . . . . . . . . . . . . 58
5–4 COOLER, FILTER,AND LINES . . . . . . . . . . . . . . . . . . . . . . . . . . 59
5–5 CHECKING CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
SECTION VI INSTALLING TRANSMISSION INTO VEHICLE
6–1 HANDLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
6–2 MOUNTING TO ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
6–3 INSTALLING TRANSMISSION MOUNTING COMPONENTS . . . . . . . 65
6–4 COUPLING TO DRIVELINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
6–5 CONNECTING OUTPUT RETARDER ACCUMULATOR . . . . . . . . . . 65
6–6 CONNECTING POWER TAKEOFF CONTROLS . . . . . . . . . . . . . . . . 66
6–7 CONNECTING PARKING BRAKE CONTROL . . . . . . . . . . . . . . . . . 67
6–8 CONNECTING COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
6–9 CONNECTING ELECTRICAL COMPONENTS . . . . . . . . . . . . . . . . . 67
6–10 CONNECTING SPEEDOMETER DRIVE . . . . . . . . . . . . . . . . . . . . 69
6–11 FILLING HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 69
6–12 INSTALLATION CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . 70
SECTION VII CHECKS AND ADJUSTMENTS
7–1 INSTALLATION CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
7–2 ROAD TESTAND VEHICLE OPERATION CHECKLIST . . . . . . . . . . 73
SECTION VIII CUSTOMER SERVICE
8–1 OWNER ASSISTANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
8–2 SERVICE LITERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

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ALLISON TRANSMISSION 3000 & 4000 PRODUCT FAMILIES 4TH GENERATION CONTROLS MECHANIC’S TIPS MANUAL – PDF DOWNLOAD:

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