Allison Transmission 4000 Series Service Manual – PDF DOWNLOAD

Description

Allison Transmission 4000 Series Service Manual

FILE DETAILS:

Allison Transmission 4000 Series Service Manual

Size: 29.6 MB
Fomat: PDF
Language: English
Brand: JCB
Type of machine: Allison Transmission 4000 Series
Type of document: Service Manual
Model: 9806-4030
Page of number: 174

ALLISON TRANSMISSION 4000 SERIES SERVICE MANUAL – PDF DOWNLOAD:

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Allison Transmission 4000 Series Service Manual

SCOPE OF MANUAL:

a. Content and Organization:

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

• Detailed instructions are provided for disassembly in Section 4, rebuild in Section 5, and reassembly in Section 6.
•  Part inspection instructions are in Section 3.
• Wear limits and spring data are in Section 7.
• Major transmission components and their functions are explained in 3000 and 4000 Product Families Principles of Operation PO4016EN.

b. Illustrations:

1. The text is supported with line drawings and cross-sectional views. Overhaul procedures are illustrated by line drawings. Cross-sections show the relationship of assembled parts. Cross-sections, exploded views, and a hydraulic schematic (transmission in Neutral) are on foldout pages in the back of the manual.
2. Illustrations show correct procedures for all models—including models not illustrated.

c. Maintenance Information:

Each task described in this manual has been successfully completed by service organizations and individuals. Not every service organization or individual possesses the required special tooling, training or experience to perform all described tasks. However, any task may be performed if the following conditions are met:

1. The organization or individual has the required knowledge of the task through:

• Formal instruction at Allison Transmission or a Distributor training facility.
• On-the-job instruction by an Allison Transmission or Distributor representative.

TABLE OF CONTENTS:

Allison Transmission 4000 Series Service Manual

Section 1 GENERAL INFORMATION
1–1 SCOPE OF MANUAL
a Content And Organization1–1
b Illustrations1–1
c Maintenance Information 1–1
1–2 SUPPLEMENTARY INFORMATION 1–5
1–3 ORDERING PARTS
a Transmission Nameplate 1–5
b Parts Catalog 1–5
1–4 GENERAL DESCRIPTION
a Major Modules1–5
b Unique Features 1–5
1–5 MAJOR COMPONENTS
a Input Module 1–6
b Torque Converter 1–6
c Power Takeoff 1–6
d Main Housing And Gear Module 1–6
e Range Clutches1–6
f Control System1–6
g Transmission Fluid Filters 1–6
h Transmission Fluid Coolers 1–6
i C6 Adapter Housing Module 1–6
j Rear Cover 1–6
k Output Retarder And Output Flange 1–6
1–6 4000 PRODUCT FAMILY MODEL
DESIGNATION CODE 1–6
1–7 EXPLODED (DISASSEMBLED)
VIEWS1–7
1–8 DIAGNOSIS
a Before Starting 1–7
b CHECK TRANS Light 1–7
c Entering Diagnostic Mode1–8
d Diagnostic Codes 1–8
e Displaying Diagnostic Codes 1–8
f Diagnostic Code Displays 1–8
g Exiting Diagnostic Mode 1–8
1–9 PRESERVATION AND STORAGE
a Storage (New Transmissions,
Before Installation)1–8
b Preservation Methods 1–8
c One Year Storage (Without Fluid)1–8
d One Year Storage (With Fluid)1–9
1–10 RESTORING TRANSMISSION
TO SERVICE
a Transmission Exterior 1–9
b Sealed Breather And Openings1–9
c New Transmissions1–9
d Stored Without Fluid 1–9
e Stored With Fluid 1–9
1–11 ELECTROMAGNETIC/RADIO
FREQUENCY INTERFERENCE 1–10
1–12 OPERATING INSTRUCTIONS1–10
1–13 SPECIFICATIONS AND DATA1–10
Section 2 PREVENTIVE MAINTENANCE
2–1 SCOPE2–1
2–2 PERIODIC INSPECTION AND CARE
a Exterior Cleaning And Inspection2–1
2–3 IMPORTANCE OF PROPER
FLUID LEVEL
a Transmission Fluid2–1
b Oil Level Sensor 2–1
c Electronic Controls And
Protection Circuits 2–1
2–4 ELECTRONIC FLUID LEVEL CHECK
(WHEN AN OPTIONAL OLS IS
PRESENT—FULL-FUNCTION
PUSHBUTTON OR LEVER SHIFT
SELECTORS)
a Fluid Level Check Procedure 2–2
2–5 MANUAL FLUID LEVEL CHECK
PROCEDURE
a Preparation2–3
b Consistency Of Readings 2–3
2–6 COLD CHECK
a Purpose2–3
b Cold Check Procedure 2–3
2–7 HOT CHECK
a Purpose2–4
b Cold Check Procedure 2–4
2–8 KEEPING FLUID CLEAN 2–4
2–9 FLUID RECOMMENDATIONS
a Fluid Type 2–5
TABLE OF CONTENTS
viii Copyright © 2007 Allison Transmission, Inc
4000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4th GENERATION
Paragraph Page Paragraph Page
2–10 FLUID AND FILTER
CHANGE INTERVALS
a Fluid And Filter Changes 2–5
b Fluid Analysis 2–7
2–11 FLUID CONTAMINATION
a Water 2–7
b Engine Coolant2–7
c Metal 2–7
2–12 FLUID AND FILTER CHANGE
PROCEDURE
a Drain Fluid2–7
b Replace Filters2–8
c Refill Transmission2–8
2–13 BREATHER
a Location And Purpose2–8
b Maintenance 2–9
2–14 TRANSMISSION STALL TEST AND
NEUTRAL COOL-DOWN CHECK
a Purpose2–9
b Stall Testing Preparation 2–9
c Performing a Transmission Stall Test 2–10
d Driving Transmission Stall Test 2–10
e Driving Transmission Stall Test
Preparation 2–10
f Performing a Driving Transmission
Stall Test 2–11
g Neutral Cool-Down Procedure 2–11
h Transmission Stall Test Results 2–11
2–15 READING CLUTCH PRESSURES
a Purpose 2–12
b Transmission And Vehicle Preparation 2–12
c Recording Data 2–12
d Comparing Recorded Data
To Specifications2–13
2–16 FLUID LEAK DIAGNOSIS
a Finding Leak 2–16
b Powder Method 2–16
c Black Light and Dye Method2–16
d Possible Points Of Fluid Leaks And
Their Causes 2–16
e Repairing Leak 2–17
2–17 OUTPUT FLANGE/YOKE AND OIL
SEAL MAINTENANCE
a Disassembly 2–17
b Assembly2–18
2–18 ON-VEHICLE MAINTENANCE 2–18
Section 3 GENERAL OVERHAUL
INFORMATION
3–1 SCOPE3–1
3–2 TOOLS AND EQUIPMENT
a Improvised Equipment3–1
b Special Tools 3–1
c Mechanic’s Tools And
Shop Equipment 3–1
3–3 REPLACEMENT PARTS
a Ordering Information 3–6
b Parts Normally Replaced
at Overhaul3–6
3–4 CAREFUL HANDLING 3–6
3–5 CLEANING AND INSPECTION
a Dirt Causes Malfunction 3–6
b Cleaning Transmission, Parts 3–6
c Cleaning Bearings3–6
d Inspecting Bearings 3–7
e Keeping Bearings Clean 3–7
f Inspecting Cast Parts and
Machined Surfaces3–7
g Inspecting Bushings and
Thrust Washers3–7
h Inspecting Sealrings and Gaskets 3–8
i Inspecting Gears 3–8
j Inspecting Splined Parts 3–8
k Inspecting Threaded Parts3–8
l Inspecting Retaining Rings3–9
m Inspecting Springs3–9
n Inspecting Clutch Plates 3–9
o Inspecting Swaged and
Interference-Fit Parts 3–9
p Inspecting Sealing Surfaces 3–9
Copyright © 2007 Allison Transmission, Inc ix
TABLE OF CONTENTS
Paragraph Page Paragraph Page
3–6 ASSEMBLY PROCEDURES
a Parts Lubrication 3–9
b Grease Used For Assembly3–9
c Sealing Compounds And
Nonsoluble Greases3–9
d Clutches And Pistons 3–9
e Threaded Plugs And Hydraulic
Fittings3–10
f Coated Threaded Fasteners 3–10
g Lip-Type Oil Seals 3–10
h Butt-Joint Sealrings 3–10
i Bearings 3–10
j Bushings 3–11
k Electrical Components 3–11
3–7 REMOVING TRANSMISSION
FROM VEHICLE
a Drain Fluid 3–11
b Disconnecting Controls 3–11
c Uncoupling Transmission From
Vehicle And Engine Driveline 3–11
d Removing The Transmission3–12
3–8 WEAR LIMITS 3–12
3–9 SPRING SPECIFICATIONS3–12
3–10 TORQUE SPECIFICATIONS 3–12
Section 4 TRANSMISSION DISASSEMBLY
4–1 SCOPE
a Section 4–1
b Procedures 4–1
c Illustrations4–1
d General Information 4–1
e Foldouts4–1
4–2 DISASSEMBLY OF TRANSMISSION
a Mounting Transmission
On Repair Stand 4–1
b Removal Of Power Takeoff 4–1
c Removal Of External Parts4–1
d Removal Of Integral Oil Cooler 4–3
e Removing Integral Retarder Sump Oil
Cooler 4–3
f Removal Of Control Valve Module 4–4
g Removal Of Torque Converter Module 4–4
h Removal Of Converter
Housing Module 4–6
i Removal Of Retarder Module
(Except 4700 And 4800 Models) 4–6
j Removal Of Retarder And Output Shaft
Module (4700 And 4800 Models) 4–7
k Removal Of Rear Cover Module (Except
4700 And 4800 Models) 4–7
l Removal Of Rear Cover And Output
Shaft Module (4700 And 4800 Models) 4–8
m Removal Of C6 Adapter Housing
Module (4700 And 4800 Models) 4–8
n Removal Of P3 Planetary Module
(4700 And 4800 Models) 4–9
o Removal Of Main Shaft Module 4–9
p Removal Of P2 Module,
C5 Clutch Plates, And P1 Module4–9
q Removal Of Front Support/
Charging Pump Module And
Rotating Clutch Module 4–10
r Removal Of C3/C4 Clutch Assembly
From Main Housing Module4–10
Section 5 MODULE REBUILD
5–1 SCOPE
a Section 5–1
b Procedures 5–1
5–2 GENERAL INFORMATION FOR
MODULE REBUILD 5–1
5–3 TORQUE CONVERTER MODULE
a Disassembly5–1
b Assembly 5–2
5–4 TORQUE CONVERTER HOUSING
MODULE (Models Without PTO Provision)
a Disassembly5–4
b Assembly 5–4
5–5 TORQUE CONVERTER HOUSING
MODULE (Models With PTO Provision)
a Disassembly 5–4
b Disassembly Of Bearing Retainer5–4
c Disassembly Of PTO Gear Assembly5–4
d Assembly Of PTO Gear Assembly5–4
e Assembly Of Bearing
Retainer Assembly5–5
f Assembly 5–5
x Copyright © 2007 Allison Transmission, Inc
4000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4th GENERATION
Paragraph Page Paragraph Page
5–6 FRONT SUPPORT AND OIL PUMP MODULE
a Disassembly 5–5
b Assembly Of Front Support 5–7
c Assembly Of Pump Housing 5–7
5–7 ROTATING CLUTCH MODULE
a Disassembly 5–8
b Assembly5–11
5–8 C3/C4 AND MAIN HOUSING MODULE
a Disassembly 5–12
b Assembly5–13
5–9 MAIN SHAFT MODULE
a Disassembly 5–13
b Assembly (Except 4700 And
4800 Models)5–14
c Assembly (4700 And 4800 Models) 5–14
5–10 P1 PLANETARY MODULE
a Disassembly 5–14
b Assembly5–14
5–11 P2 PLANETARY MODULE
a Disassembly 5–15
b Assembly5–15
5–12 P3 PLANETARY MODULE
(4700 And 4800 Models)
a Disassembly 5–16
b Assembly5–16
5–13 C6 ADAPTER HOUSING MODULE
(4700 And 4800 Models)
a Disassembly Of Ring Gear and Hub
Assembly5–17
b Disassembly 5–17
c Disassembly Of P4 Planetary Carrier
Assembly5–17
d Disassembly Of Remaining C6 Parts5–17
e Assembly5–18
f Assembly Of P4 Planetary Carrier
Assembly5–19
g Assembly Of C6 Clutch 5–20
5–14 RETARDER AND P3 PLANETARY MODULE
a Disassembly Of Retarder Valve Body5–20
b Disassembly Of Temperature Sensor5–20
c Disassembly Of Retarder Housing 5–21
d Disassembly Of P3 Planetary
Carrier Assembly5–22
e Disassembly Of Retarder
Stator Assembly 5–22
f Assembly Of Retarder Stator5–23
g Assembly Of P3 Planetary
Carrier Assembly5–23
h Assembly Of Retarder Housing
Assembly5–23
i Assembly Of The Retarder Valve Body 5–24
5–15 RETARDER AND OUTPUT SHAFT
MODULE (4700 And 4800 Models Equipped
With Retarder)
a Disassembly Of Retarder Valve Body 5–25
b Disassembly Of Temperature Sensor5–25
c Disassembly Of Retarder Housing 5–25
d Completion Of Retarder Housing
Disassembly 5–26
e Assembly Of Output Shaft Assembly 5–26
f Disassembly Of Retarder Stator
Assembly5–26
g Assembly Of Retarder Stator5–26
h Assembly Of Retarder Housing 5–27
i Assembly Of Output Shaft Assembly 5–27
j Completion Of Retarder Housing
Assembly5–27
k Assembly Of Retarder Valve Body 5–28
5–16 REAR COVER MODULE (Models Equipped
With Rear Cover, Except 4700 And 4800
Models)
a Disassembly 5–28
b Disassembly Of P3 Planetary
Carrier Assembly5–29
c Completion Of Rear Cover
Disassembly 5–30
d Beginning Rear Cover Assembly5–30
e Assembly Of P3 Planetary
Carrier Assembly5–30
f Completion Of Rear Cover Assembly5–31
5–17 REAR COVER AND OUTPUT SHAFT
MODULE (4700 And 4800 Models Equipped
With Rear Cover)
a Disassembly 5–32
b Disassembly Of Output Shaft
Assembly5–32
Copyright © 2007 Allison Transmission, Inc xi
TABLE OF CONTENTS
Paragraph Page Paragraph Page
c Completion Of Rear Cover
Disassembly 5–32
d Beginning Rear Cover Assembly5–32
e Assembly Of Output Shaft
Assembly 5–33
f Completion Of Rear Cover Assembly 5–33
5–18 CONTROL VALVE MODULE
a Removal Of Filters 5–34
b Removal Of Electrical Components
And Sensors 5–35
c Disassembly Of Solenoid Valve Body 5–35
d Disassembly Of C6 Control Valve
Body 5–36
e Disassembly Of Main
Valve Body 5–36
f Disassembly Of Channel Plate 5–37
g Assembly Of Channel Plate 5–37
h Assembly Of Main Valve Body 5–37
i Assembly Of C6 Control Valve Body 5–38
j Assembly Of Solenoid Valve Body5–38
k Installation Of Electrical Components
And Sensors 5–38
l Install Filters 5–38
Section 6 TRANSMISSION ASSEMBLY
6–1 SCOPE
a Section 6–1
b Procedures 6–1
c Illustrations6–1
d General Information 6–1
e Foldouts6–1
6–2 ASSEMBLY OF TRANSMISSION
a Assembly Of Main Housing Module 6–1
b Installation Of Rotating Clutch Module 6–1
c Installation Of Front Support/
Charging Pump Module 6–2
d Installation Of P1 Planetary Module 6–2
e Installation Of P2 Planetary Module 6–2
f Installation Of C5 Clutch Pack6–2
g Installation Of Main Shaft Module
(Except 4700 And 4800 Models) 6–2
h Installation Of Main Shaft Module
(4700 And 4800 Models) 6–3
i Main Shaft Selective Shim
Measurement (Close Ratio Models) 6–3
j Main Shaft Selective Shim
Measurement (Wide Ratio Models) 6–4
k Installation Of P3 Planetary Module
(4700 And 4800 Models With Retarder) 6–5
l Installation Of C6 Adapter Housing
Module (4700 And 4800 Models With
Retarder) 6–5
m P3 Planetary Selective Shim
Measurement (4700 And 4800 Models
With Retarder)6–6
n P3 Planetary Selective Shim
Measurement (4700 And 4800 Models
With Rear Cover) 6–7
o Installation Of Remainder Of P3 Planetary
Module and C6 Adapter Housing Module
(4700 And 4800 Models) 6–8
p Installation Of Tolerance Rings
Module (4700 And 4800 Models With
Retarder) 6–9
q Installation Of Retarder Module (Except
4700 And 4800 Models) 6–9
r Installation Of Retarder and Output
Shaft Module (4700 And 4800 Models
With Retarders) 6–10
s Installation Of Rear Cover Module
(Except 4700 And 4800 Models)6–11
t Installation Of Rear Cover Module
(4700 And 4800 Models)6–11
u Installation Of Converter Housing
Module6–13
v Installation Of Torque Converter
Module6–13
w Installation Of Control Module 6–16
x Installing Integral Oil Cooler 6–16
y Installing Integral Retarder Sump Oil
Cooler6–17
z Installation Of Externally
Mounted Parts6–18
aa Installation Of Power Takeoff6–19
ab Removal Of Transmission
From Repair Stand6–19
xii Copyright © 2007 Allison Transmission, Inc
4000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4th GENERATION
Paragraph Page Paragraph Page
Section 7 WEAR LIMITS AND
SPRING DATA
7–1 WEAR LIMITS DATA
a Maximum Variations 7–1
b Cleaning and Inspection 7–1
7–2 SPRING DATA
a Spring Replacement 7–1
b Inspection 7–1
Section 8 CUSTOMER SERVICE
8–1 OWNER ASSISTANCE 8–1
8–2 SERVICE LITERATURE8–2

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