Allison Transmission MT1321EN AT 500 & AT 1500 Series Transmission Mechanic’s Tips Manual – PDF DOWNLOAD

Description

Allison Transmission MT1321EN AT 500 & AT 1500 Series Transmission Mechanic’s Tips Manual – PDF DOWNLOAD

DESCRIPTION:

Allison Transmission MT1321EN AT 500 & AT 1500 Series Transmission Mechanic’s Tips Manual – PDF DOWNLOAD

AT 540, AT 543
AT 542, AT 542N, AT 542R, AT 542NR
AT 545, AT 545N, AT 545R, AT 545NR,
AT 542NFE
AT 1542, AT 1542P, AT 1542NP
AT 1545, AT 1545P, AT 1545NP

PREFACE :

This handbook is a ready reference for the mechanic removing, installing, or
maintaining AT Series Automatic Transmissions. All features of both the vehicle and
transmission that become involved in the installation procedures are discussed. The
information presented will help the mechanic to remove, install, and maintain the
transmission in a manner that assures satisfactory operation and long service life.

TABLE OF CONTENTS:

Allison Transmission MT1321EN AT 500 & AT 1500 Series Transmission Mechanic’s Tips Manual – PDF DOWNLOAD

MT1321EN…………………………………………………………………………………………….. 0
TITLE PAGE……………………………………………………………………………………….. 2
WARNINGS, CAUTIONS, AND NOTES………………………………………………………………………. 3
TABLE OF CONTENTS…………………………………………………………………………………. 4
PREFACE & TRADEMARKS USED………………………………………………………………………….. 6
REPRESENTATIVE VIEWS………………………………………………………………………………. 7
Model AT 542 Transmission — Left-Front View………………………………………………………. 7
Model AT 545 Transmission — Right-Front View……………………………………………………… 7
Model AT 545R Transmission — Right-Front View…………………………………………………….. 7
PREVENTIVE MAINTENANCE…………………………………………………………………………….. 8
1–1. PERIODIC INSPECTION AND CARE……………………………………………………………….. 8
1–2. IMPORTANCE OF PROPER FLUID LEVEL……………………………………………………………. 8
1–3. DIPSTICK MARKINGS…………………………………………………………………………. 8
Figure 1–1. Typical Dipstick Markings……………………………………………………….. 9
Figure 1–2. How Fluid Levels Are Established…………………………………………………. 9
1–4. FLUID CHECK PROCEDURE………………………………………………………………………10
1–5. KEEPING FLUID CLEAN………………………………………………………………………..11
1–6. RECOMMENDED AUTOMATIC TRANSMISSION FLUID AND VISCOSITY GRADE……………………………………11
Table 1–1. Transmission Fluid Operating Temperature Requirements…………………………………12
1–7. FLUID AND FILTER CHANGE INTERVALS……………………………………………………………12
Table 1–2. Fluid and Filter Cha nge Intervals …………………………………………………13
1–8. FLUID AND FILTER CHANGE PROCEDURE……………………………………………………………13
Table 1–3. Transmission Fluid Refill Capacities………………………………………………..15
1–9. FLUID CONTAMINATION………………………………………………………………………..15
Table 1–4. Fluid Oxidation Measurement Limits………………………………………………….16
1–10. AUXILIARY FILTER………………………………………………………………………….16
Table 1–5. Auxiliary Filter Recommendations……………………………………………………17
1–11. BREATHER…………………………………………………………………………………17
1–12. TRANSMISSION STALL TEST AND NEUTRAL COOL-DOWN CHECK…………………………………………..17
REMOVING TRANSMISSION………………………………………………………………………………20
2–1. DRAINING TRANSMISSION………………………………………………………………………20
2–2. DISCONNECTING CONTROLS……………………………………………………………………..20
2–3. UNCOUPLING ENGINE FROM DRIVELINE…………………………………………………………….21
Figure 2–1. Typical Coupling Methods…………………………………………………………21
2–4. REMOVING MOUNTING BOLTS…………………………………………………………………….22
2–5. REMOVING TRANSMISSION………………………………………………………………………22
2–6. REPAIR INSTRUCTIONS………………………………………………………………………..22
Figure 2–2. Location of Torque Converter Retaining Strap……………………………………….23
PREPARING TRANSMISSION FOR INSTALLATION………………………………………………………………24
3–1. CHECKING INPUT COMPONENTS…………………………………………………………………..24
3–2. CHECKING TORQUE CONVERTER POSITION…………………………………………………………..24
Figure 3–1. Converter Position Measurements…………………………………………………..25
3–3. INSTALLING PARKING BRAKE AND OUTPUT FLANGE……………………………………………………25
3–4. INSTALLING SHIFT SELECTOR LEVER……………………………………………………………..26
Figure 3–2. Tightening Selector Lever Nut…………………………………………………….27
3–5. INSTALLING POWER TAKEOFF (PTO)………………………………………………………………27
Figure 3–3. Measuring Turbine-Driven PTO Backlash……………………………………………..28
3–6. INSTALLING SHIFT MODULATION CONTROL………………………………………………………….28
Figure 3–4. View at PTO Opening……………………………………………………………..29
3–7. INSTALLING FILL TUBE AND DRAIN PLUG………………………………………………………….29
3–8. INSTALLING NEUTRAL START AND REVERSE SIGNAL SWITCHES…………………………………………..30
3–9. INSTALLING RETARDER CONTROLS………………………………………………………………..30
3–10. CHECKING BREATHER…………………………………………………………………………31
Figure 3–5. Breather Configurations………………………………………………………….31
PREPARING VEHICLE FOR TRANSMISSION INSTALLATION……………………………………………………….32
4–1. CHECKING FLEXPLATE, ENGINE FEATURES………………………………………………………….32
Figure 4–1. Tooling Used to Determine the Adaptation Measurements of an AT 500 Series Transmission….32
Table 4–1. Measurements……………………………………………………………………..33
4–2. CHECKING CHASSIS, DRIVELINE…………………………………………………………………34
4–3. CHECKING COOLER, TUBES, HOSES, FITTINGS………………………………………………………34
4–4. CHECKING CONTROLS………………………………………………………………………….35
INSTALLING TRANSMISSION INTO VEHICLE…………………………………………………………………36
5–1. HANDLING………………………………………………………………………………….36
5–2. COUPLING TO ENGINE…………………………………………………………………………36
Figure 5–1. Pilot Tool for Installation (AT 500, AT 1500)………………………………………37
5–3. INSTALLING TRANSMISSION MOUNTING COMPONENTS…………………………………………………..37
5–4. COUPLING TO DRIVELINE………………………………………………………………………38
5–5. INSTALLING VACUUM OR AIR MODULATOR CONTROL……………………………………………………38
Figure 5–2. Proper Relation of Vacuum Hose to Modulator Control…………………………………38
5–6. CONNECTING COOLER, VACUUM LINES, AIR LINES……………………………………………………39
5–7. CONNECTING RETARDER CONTROLS………………………………………………………………..39
Figure 5–3. AT 500R External Connections……………………………………………………..39
5–8. CONNECTING SHIFT SELECTOR CONTROL……………………………………………………………40
Figure 5–4. Identification of Internal Selector Levers…………………………………………40
5–9. INSTALLING, ADJUSTING MECHANICAL MODULATOR CONTROL…………………………………………….41
5–10. CONNECTING POWER TAKEOFF CONTROLS…………………………………………………………..42
5–11. CONNECTING PARKING BRAKE CONTROL……………………………………………………………42
5–12. CONNECTING SPEEDOMETER DRIVE……………………………………………………………….42
5–13. FILLING THE TRANSMISSION…………………………………………………………………..43
CHECKS AND ADJUSTMENTS……………………………………………………………………………..44
6–1. INSTALLATION CHECKLIST……………………………………………………………………..44
6–2. ROAD TEST AND VEHICLE OPERATION CHECKLIST…………………………………………………….47
CUSTOMER SERVICE…………………………………………………………………………………..49
7–1. OWNER ASSISTANCE…………………………………………………………………………..49
7–2. SERVICE LITERATURE…………………………………………………………………………51
Table 7–1. Service Literature………………………………………………………………..51

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