Allison Transmission
Allison 4
th
Generation Controls
Mechanic’s
Tips
2005 FEBRUARY
Rev. 1 2005 SEPTEMBER
MT4015EN
3000 Product Family (Except 3700 SP)
4000 Product Family
Printed in USA Copyright © 2005 General Motors Corporation
2
NOTES
TABLE OF CONTENTS
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 FLUIDAND 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 TUBE AND SEAL ...................... 52
4–5 CHECKING PLUGS AND OPENINGS ...................... 53
3
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 TEST AND VEHICLE OPERATION CHECKLIST .......... 73
SECTION VIII CUSTOMER SERVICE
8–1 OWNER ASSISTANCE ................................ 75
8–2 SERVICE LITERATURE ............................... 75
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TRADEMARK USAGE
The following trademarks are the property of the companies indicated:
• Allison DOC™ is a trademark of General Motors Corporation.
• DEXRON
®
is a registered trademark of the General Motors Corporation.
• TranSynd™ is a trademark of Castrol Ltd.
5
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Allison 3000 4000 Series Troubleshooting Manual 4TH Gen
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Description
The Allison 3000 4000 Series Troubleshooting Manual 4TH Generation covers a range of model types including 3000 HS, 3000 RDS, 3000 EVS, 3000 MH, 3000 PTS, 3000 TRV, 3200 SP, 3200 TRV, 3500 RDS, 3500 EVS, 3500 SP, 3700 SP, B 300(P)(R), B 400(P)(R), T 200, T 300, 4000 EVS, 4000 HS, 4000 MH, 4000 RDS, 4000 TRV, 4500 EVS, 4500 HS, 4500 RDS, 4500 SP, 4500 TRV, 4700 EVS, 4700 RDS, 4700 OFS, 4800 EVS, B 500, B 500P, B 500R, B 500PR, T 425, and T 450.
The manual contains the following sections:
- SAFETY INFORMATION
- GENERAL INFORMATION
- DEFINITIONS AND ABBREVIATIONS
- BASIC KNOWLEDGE
- WIRE TESTING PROCEDURES
- OIL LEVEL SENSOR
- DIAGNOSTIC CODES
- INPUT AND OUTPUT FUNCTIONS
- GENERAL TROUBLESHOOTING OF PERFORMANCE COMPLAINTS
- APPENDICES
The manual consists of 861 pages and is available in English. It is compatible with Win95, 98, ME, XP, Vista, 7, Linux, and MAC operating systems.
We offer a range of Repair Manuals, Service Manuals, and Workshop Manuals for various vehicles and equipment, providing instant access without shipping costs or the need to wait for a CD-ROM. If you are unable to find a specific manual, please contact our customer support team via the Contact Seller link with the details, and we will endeavor to source it for you.
