Allison Transmission 3000 & 4000 Series Gearbox Complete Workshop Service Repair Manual

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 4

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

Allison Transmission 3000 & 4000 Series Gearbox Complete Workshop Service Repair Manual

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