Allison Transmission HD4060 Service Manual

Mechanic’s Tips

3000 and 4000 Product Families

MT3004EN

Mechanic’s

2006 MARCH

Tips

MT3004EN

Allison Transmission

Allison WTEC III Controls (Except 3000 P

3000 Product Family 4000 Product Family

roduct Family 7-Speed)

Alli son Tra nsmis sion, Inc.

P.O. Box 894 Indi anapo lis, India na 46206- 0894

www.al lison transmission.com

Printed in USA

NOTES

SECTION I INTRODUCTION

1–1 ABOUT THIS MANUAL ............................... 7

SECTION II PREVENTIVE MAINTENANCE

2–1 PERIODIC INSPECTION AND CARE ...................... 20

2–2 IMPORTANCE OF PROPER TRANSMISSION FLUID LEVEL .......20

2–3 TRANSMISSION FLUID TEST ...........................21

2–4 KEEPING FLUID CLEAN ..............................27

2–5FLUIDRECOMMENDATIONS...........................27

2–6 TRANSMISSION FLUID AND FILTER CHANGE INTERVALS ...... 28

2–7 TRANSMISSION FLUID CONTAMINATION ..................32

2–8 TRANSMISSION FLUID AND FILTER CHANGE PROCEDURE ..... 35

2–9 FLUID LEAK DIAGNOSIS ............................. 37

2–10 BREATHER ...................................... 40

2–11 TROUBLESHOOTING ............................... 40

2–12 TRANSMISSION STALL TEST AND NEUTRAL COOL-DOWN

CHECK ......................................... 45

SECTION III REMOVING TRANSMISSION

3–1 DRAINING TRANSMISSION ............................51

3–2 DISCONNECTING CONTROLS .......................... 51

3–3 UNCOUPLING FROM DRIVELINE, ENGINE, AND VEHICLE ...... 52

3–4 REMOVING THE TRANSMISSION ........................53

3–5 REMOVING OUTPUT FLANGE OR YOKE ...................53

SECTION IV TRANSMISSION PREPARATION

4–1 INSPECTING INPUT COMPONENTS ...................... 55

4–2 INSTALLING OUTPUT FLANGE OR YOKE ..................55

4–3 INSTALLING PTO ...................................56

4–4 INSTALLING FILL TUBE AND SEAL ...................... 57

4–5 INSPECTING PLUGS AND OPENINGS ..................... 58

SECTION V PREPARING VEHICLE FOR TRANSMISSION

INSTALLATION

5–1 ENGINE, TRANSMISSION ADAPTATION REQUIREMENTS ....... 59

5–2 CHECKING FLEXPLATE DRIVE ASSEMBLY .................62

5–3 CHASSIS AND DRIVELINE INSPECTION ................... 63

5–4 COOLER, FILTER, AND LINES .......................... 64

5–5 INSPECTING CONTROLS ............................. 65

SECTION VI INSTALLING TRANSMISSION INTO VEHICLE

6–1 HANDLING .......................................69

6–2 MOUNTING TO ENGINE .............................. 69

6–3 INSTALLING TRANSMISSION MOUNTING COMPONENTS ....... 70

6–4 COUPLING TO DRIVELINE ............................ 70

6–5 CONNECTING OUTPUT RETARDER ACCUMULATOR .......... 70

6–6 CONNECTING POWER TAKEOFF CONTROLS ................71

6–7 CONNECTING PARKING BRAKE CONTROL .................72

6–8 CONNECTING COOLER .............................. 72

6–9 CONNECTING ELECTRICAL COMPONENTS .................72

6–10 CONNECTING SPEEDOMETER DRIVE ....................74

6–11 FILLING HYDRAULIC SYSTEM ........................ 75

6–12 INSTALLATION INSPECTION LIST ...................... 75

SECTION VII INSPECTIONS AND ADJUSTMENTS

7–1 INSTALLATION INSPECTION LIST ....................... 76

7–2 ROAD TEST AND VEHICLE OPERATION INSPECTION LIST ...... 78

SECTION VIII CUSTOMER SERVICE

8–1 OWNER ASSISTANCE ................................ 80

8–2 SERVICE LITERATURE ............................... 80

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.

• LPS Electro Contact Cleaner®is a registered trademark of LPS

Laboratories.

WARNINGS, CAUTIONS, NOTES

IT IS YOUR RESPONSIBILITY to be completely familiar with the warnings and cautions described in this handbook. It is, however, important to understand that these warnings and cautions are not exhaustive. Allison Transmission could not possibly know, evaluate, and advise the service trade of all conceivable ways in which service might be done or of the possible hazardous consequences of each way. The vehicle manufacturer is responsible for providing information related to the operation of vehicle systems (including appropriate warnings, cautions, and notes). Consequently, Allison Transmission has not undertaken any such broad evaluation. Accordingly, ANYONE WHO USES A SERVICE PROCEDURE OR TOOL WHICH IS NOT RECOMMENDED BY ALLISON TRANSMISSION OR THE VEHICLE MANUFACTURER MUST ﬁrst be thoroughly satisﬁed that neither personal safety nor equipment safety will be jeopardized by the service methods selected.

Proper service and repair is important to the safe, reliable operation of the equipment. The service procedures recommended by Allison Transmission (or the vehicle manufacturer) and described in this handbook are effective methods for performing service operations. Some of these service operations require the use of tools specially designed for the purpose. The special tools should be used when and as recommended.

The following three types of headings are used in this manual to attract your attention.

WARNING: A warning is used when an operating procedure, practice, etc., if not correctly followed, could result in personal injury or loss of life.

CAUTION: A caution is used when an operating procedure, practice, etc., if not strictly observed, could result in damage to or destruction of equipment.

NOTE: A note is used when an operating procedure, practice, etc., is essential to highlight.

INTRODUCTION Section I

1–1. ABOUT THIS MANUAL

This handbook is a mechanic’s reference for maintaining, removing, or installing the 3000 and 4000 Product Families on-highway transmission with a WTEC III control system. WTEC III controls were optional on the 3000 and 4000 Product Families on-highway transmission units built in 1997, but became standard on units built starting in 1998.

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 promotes 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 handbook refers to all 3000 and 4000 Product Families on-highway transmissions, except 7-speed models. The differences between the various transmissions are explained as required.

MAIN SHAFT MODULE

• MAIN SHAFT

• P2 SUN

• P3 SUN

MAIN HOUSING MODULE

• MAIN HOUSING

• C3 CLUTCH

• C4 CLUTCH

• C5 CLUTCH

REAR COVER MODULE

• OUTPUT SHAFT

• P3

• C5 PISTON

P2 MODULE

P1 MODULE

CONTROL MODULE

• ELECTRO-HYDRAULIC

CONTROLS

OIL LEVEL SENSOR

ROTATING CLUTCH MODULE

V03350.08.00

• C1 CLUTCH

• C2 CLUTCH

• TURBINE SHAFT

FRONT SUPPORT/OIL PUMP MODULE

• FRONT SUPPORT

• OIL PUMP

CONVERTER MODULE

• TURBINE

• PUMP

• LOCKUP

CLUTCH/DAMPER

• STATOR CONVERTER HOUSING MODULE

Figure 1–1. 3000 Product Family Transmission

with PTO—Cross Section

• CONVERTER HOUSING

• PTO DRIVE GEAR

MAIN SHAFT MODULE

MAIN SHAFT

P2 SUN

P3 SUN

MAIN HOUSING MODULE

MAIN HOUSING

C3 CLUTCH

C4 CLUTCH

C5 CLUTCH

REAR COVER MODULE

OUTPUT SHAFT

P3 MODULE

C5 PISTON

P1 MODULE

P2 MODULE

V07286.02.00

CONTROL MODULE

ELECTRO-HYDRAULIC CONTROLS

ROTATING CLUTCH MODULE

C1 CLUTCH

C2 CLUTCH

TURBINE SHAFT

OIL PUMP

FRONT SUPPORT

PUMP

STATOR

LOCKUP

FRONT SUPPORT/OIL PUMP MODULE

TURBINE

CLUTCH/DAMPER

CONVERTER MODULE

CONVERTER HOUSING

CONVERTER HOUSING MODULE

Figure 1–2. 3000 Product Family Transmission—Cross Section

V07287.06.00

RETARDER MODULE

STATOR ASSEMBLY

ROTOR

HOUSING ASSEMBLY

MAIN HOUSING MODULE

MAIN HOUSING

C3 CLUTCH

C4 CLUTCH

C5 CLUTCH

OIL PUMP

MAIN SHAFT MODULE

MAIN SHAFT

P2 SUN

P3 SUN

P3 MODULE

P2 MODULE

P1 MODULE

CONTROL MODULE

ELECTRO-HYDRAULIC CONTROLS

ROTATING CLUTCH MODULE

C1 CLUTCH

C2 CLUTCH

TURBINE SHAFT

FRONT SUPPORT

PUMP

STATOR

LOCKUP

FRONT SUPPORT/OIL PUMP MODULE

TURBINE

CONVERTER MODULE

CLUTCH/DAMPER

Figure 1–3. 4000 Product Family Transmission

with Retarder—Cross Section

CONVERTER HOUSING

CONVERTER HOUSING MODULE

MAIN SHAFT MODULE

MAIN SHAFT

MAIN HOUSING MODULE

MAIN HOUSING

C3 CLUTCH

C4 CLUTCH

C5 CLUTCH

OIL PUMP

P2 SUN

P3 SUN

REAR COVER MODULE

OUTPUT SHAFT

P3 MODULE

C5 PISTON

P2 MODULE

P1 MODULE

V07288.03.00

CONTROL MODULE

ELECTRO-HYDRAULIC CONTROLS

ROTATING CLUTCH MODULE

C1 CLUTCH

C2 CLUTCH

TURBINE SHAFT

FRONT SUPPORT

FRONT SUPPORT/OIL PUMP MODULE

PUMP

STATOR

LOCKUP

TURBINE

CONVERTER MODULE

CLUTCH/DAMPER

CONVERTER HOUSING MODULE

Figure 1–4. 4000 Product Family Transmission

with PTO—Cross Section

PTO DRIVE GEAR

CONVERTER HOUSING

GNISUOH RETPADA 6C •

GNISUOH RETPADA 6C

ELUDOM

ELUDOM GNISUOH NIAM

GNISUOH NIAM •

ELUDOM PMUP LIO/TROPPUS TNORF

TROPPUS TNORF •

PMUP LIO •

REVOC RAER

ELUDOM

ELUDOM 4P •

•REVOC RAER

•TFAHS TUPTUO

•HCTULC 6C

HCTULC 3C •

HCTULC 4C •

HCTULC 5C •

TFAHS NIAM

NUS 3P •

NUS 2P •

ELUDOM

•TFAHS NIAM

ELUDOM 3P

V05641.03.00

ELUDOM 2P

ELUDOM 1P

ELUDOM RETREVNOC

ENIBRUT •

PUKCOL •

REPMAD

ROTATS •

PMUP •

/HCTULC

Figure 1–5. 4000 Product Family Transmission

7-Speed—Cross Section

ELUDOM HCTULC GNITATOR

ELUDOM GNISUOH

RETREVNOC

TFAHS ENIBRUT •

HCTULC 1C •

HCTULC 2C •

•GNISUOH RETREVNOC

OUTPUT

SPEED

SENSOR

BREATHER

ASSEMBLY PADS

PTO PROVISION

INPUT SPEED SENSOR

FEEDTHROUGH HARNESS CONNECTOR

COOLER PORTS

NOTE: Inch Series Threads

TORQUE CONVERTER WITH LOCKUP CLUTCH AND TORSIONAL DAMPER

MAIN-PRESSURE TAP

NOTE: Inch Series Threads

RIGHT-REAR VIEW

BREATHER

PTO PROVISION

(AVAILABLE BOTH SIDES)

LEFT-FRONT VIEW

NAMEPLATE

FEEDTHROUGH HARNESS CONNECTOR

ASSEMBLY PADS (BOTH SIDES)

MAIN-PRESSURE TAP

NOTE: Inch Series Threads

V07289.02.00

Figure 1–6. 3000 Product Family Transmission with PTO

FEEDTHROUGH

HARNESS

CONNECTOR

COOLER PORTS

NOTE: Inch Series Threads

ASSEMBLY PADS

BREATHER

INPUT SPEED SENSOR

NAMEPLATE

MAIN-PRESSURE TAP

NOTE: Inch Series Threads

RIGHT-REAR VIEW

BREATHER

TORQUE CONVERTER

WITH LOCKUP CLUTCH

AND TORSIONAL DAMPER

MAIN-PRESSURE TAP

NOTE: Inch series threads

ASSEMBLY PADS (BOTH SIDES)

TO RETARDER ACCUMULATOR

OIL FILL TUBE AND DIPSTICK (AVAILABLE ON BOTH SIDES

LEFT-FRONT VIEW

Figure 1–7. 3000 Product Family Transmission with Retarder

OUTPUT RETARDER

)

V07290.01.00

BREATHER

MAIN-PRESSURE TAP

NOTE: Inch Series Threads

TACHOGRAPH PROVISION

NOTE: Metric Series Threads

ASSEMBLY PADS

FEEDTHROUGH HARNESS CONNECTOR

OUTPUT SPEED SENSOR

RETARDER VALVE BODY CONNECTOR

SPEEDOMETER PROVISION

NOTE: Inch Series Threads

LEFT-REAR VIEW

TORQUE CONVERTER WITH LOCKUP CLUTCH AND TORSIONAL DAMPER

MAIN-PRESSURE TAP

LEFT-FRONT VIEW

BREATHER

NOTE: Inch series threads

COOLER PORTS

NOTE: Inch Series Threads

ASSEMBLY PADS (BOTH SIDES)

OUTPUT RETARDER

TO RETARDER ACCUMULATOR

OIL FILL TUBE AND DIPSTICK (AVAILABLE ON BOTH SIDES

V07300.01.00

)

Figure 1–8. 3000 Product Family Transmission with Retarder and

Provisions for Tachograph and Speedometer

BREATHER

MAIN-PRESSURE TAP

NOTE: Inch Series Threads

ASSEMBLY PADS

FEEDTHROUGH HARNESS CONNECTOR

OUTPUT SPEED SENSOR

RETARDER VALVE BODY CONNECTOR

TACHOGRAPH PROVISION

NOTE: Inch Series Threads

LEFT-REAR VIEW

TORQUE CONVERTER WITH LOCKUP CLUTCH AND TORSIONAL DAMPER

LEFT-FRONT VIEW

BREATHER

MAIN-PRESSURE TAP

NOTE: Inch series threads

COOLER PORTS

NOTE: Inch Series Threads

ASSEMBLY PADS (BOTH SIDES)

OUTPUT RETARDER

TO RETARDER ACCUMULATOR

OIL FILL TUBE AND DIPSTICK (AVAILABLE ON BOTH SIDES

V07401.02.00

)

Figure 1–9. 3000 Product Family Transmission with Retarder and

Provisions for Tachograph and Sump Cooler

FEEDTHROUGH

HARNESS

CONNECTOR

OUTPUT SPEED

SENSOR

COOLER PORTS

MOUNTING PAD

(BOTH SIDES)

PTO (TOP RIGHT POSITION)

SHIPPING BRACKET (3)

MOUNTING PAD

ENGINE SPEED SENSOR

TURBINE SPEED SENSOR

FILL TUBE

NAMEPLATE

RIGHT-REAR VIEW

FEEDTHROUGH HARNESS CONNECTOR

(BOTTOM LEFT

MAIN-PRESSURE TAP

PTO

POSITION)

COOLER PORTS

LEFT-REAR VIEW

Figure 1–10. 4000 Product Family Transmission with PTO

V07291.00.01

RETARDER

PTO (TOP RIGHT POSITION)

FEEDTHROUGH

HARNESS

CONNECTOR

NAMEPLATE

FILL TUBE

TURBINE

SPEED

SENSOR

MOUNTING PADS (BOTH SIDES)

ENGINE SPEED SENSOR

RIGHT-FRONT VIEW

MOUNTING PADS (BOTH SIDES)

PTO (TOP RIGHT POSITION)

FEEDTHROUGH HARNESS CONNECTOR

RETARDER

SUMP COOLER

PTO (BOTTOM LEFT

POSITION)

MAIN-PRESSURE TAP

PROVISION

COOLER PORTS

LEFT-REAR VIEW

V07292.03.00

Figure 1–11. 4000 Product Family Transmission with Retarder and PTO

MOUNTING PADS (BOTH SIDES)

PTO (TOP RIGHT POSITION)

FEEDTHROUGH HARNESS CONNECTOR

C6 ADAPTER HOUSING

REAR COVER

PTO (BOTTOM LEFT

POSITION)

MAIN-PRESSURE TAP

PTO (BOTTOM LEFT

POSITION)

MAIN-PRESSURE TAP

LEFT-REAR

MOUNTING PADS (BOTH SIDES)

PTO (TOP RIGHT POSITION)

C6 ADAPTER HOUSING

RETARDER

SUMP COOLER PROVISION

COOLER PORTS

LEFT-REAR

V07399.00.02

Figure 1–12. 4000 Product Family 7-Speed Transmission

with PTO (Top) and 7-Speed with PTO and Retarder (Bottom)

Section II

2–1. PERIODIC INSPECTION AND CARE

Clean and inspect the exterior of the transmission at regular intervals. Severity of service and operating conditions determine the frequency of these inspections. Inspect the transmission for:

• Loose bolts—transmission and mounting components

• Fluid leaks—repair immediately

• Loose, dirty, or improperly adjusted throttle sensor

• Damaged or loose hoses

• Worn, frayed, or improperly routed electrical harnesses

• Worn or frayed electrical connections

• Dented, worn or out-of-phase driveline U-joints and slip ﬁttings

• Clogged or dirty breather

Inspect the vehicle cooling system occasionally for evidence of transmission ﬂuid. Transmission ﬂuid in the vehicle cooling system indicates a faulty oil cooler.

CAUTION: When welding on the vehicle:

• DO NOT WELD on the vehicle without disconnecting all control

system wiring harness connectors from the ECU.

• DO NOT WELD on the vehicle without disconnecting ECU

battery power and ground leads.

• DO NOT WELD on any control components.

• DO NOT CONNECT welding cables to any control components.

PREVENTIVE

MAINTENANCE

A label (ST2067EN) describing on-vehicle welding precautions is available from your authorized Allison service dealer and should be installed in a conspicuous place. A vehicle used in a vocation that requires frequent modiﬁcations or repairs involving welding must have an on-vehicle welding label.

2–2. IMPORTANCE OF PROPER TRANSMISSION FLUID LEVEL

Transmission ﬂuid cools, lubricates, and transmits hydraulic power. Always maintain proper ﬂuid level. If ﬂuid level is too low, the torque converter and clutches do not receive an adequate supply of ﬂuid and the transmission overheats.

If the level is too high, the ﬂuid aerates—causing the transmission to shift erratically and overheat. Fluid may be expelled through the breather or dipstick tube when the ﬂuid level is too high.

2–3. TRANSMISSION FLUID TEST

a. Electronic Fluid Test Procedure. Fluid level can be electronically displayed on a pushbutton (non-strip type) shift selector, lever shift selector, or Allison DOC™ For PC–Service Tool if there is an oil level sensor (OLS) installed and “autodetected” by the WTEC III control system. Frequently test for the presence of oil level diagnostics if the transmission is known to contain an OLS.

If an OLS is not detected during the ﬁrst 49 engine starts, the WTEC III system concludes that no OLS is present. If an OLS is known to be present, but has not been “autodetected”, then troubleshoot the OLS circuit.

After the OLS circuit is repaired, reset “autodetect” or manually select the OLS function using the Allison DOC™ service tool and then reset autodetect (refer to TS2973EN, WTEC III Troubleshooting Manual for detailed troubleshooting procedures).

• Displaying Fluid Level Information. Use the following procedure to display

ﬂuid level information (refer to Figure 2–1).

— For a pushbutton shift selector: Simultaneously press the ↑ (Up) and

↓ (Down) arrow buttons once.

— For a lever shift selector: Press the DISPLAY MODE/DIAGNOSTIC

button once.

— For Allison DOC™ For PC–service tool: Connect the Allison DOC™

For PC–service tool to the diagnostic tool connector on the wiring harness and scroll down the DIAGNOSTIC DATA LIST to read the OLS information.

• Fluid Level Display Criteria. As soon as ﬂuid level information is

requested, the ECU determines if conditions are right to allow display. Certain operating conditions must have been met for a period of two minutes before ﬂuid level is displayed. These operating conditions are:

— Engine at idle — Sump ﬂuid at operating temperature 60–104°C (140–220°F) — Transmission output shaft stopped — Transmission in neutral — OLS functioning properly

HOLD OVERRIDE BUTTON

MODE

2 3 4 5 D N R

DIGITAL DISPLAY

DIAGNOSTIC BUTTON

SIX-SPEED, LEFT-HAND

LEVER SELECTOR

MODE INDICATOR

(LED)

MODE BUTTON

MODE ID

✽

DISPLAY MODE/

SIX-SPEED, RIGHT-HAND

MODE

N D 5 4 3 2 1

LEVER SELECTOR

DIGITAL DISPLAY MODE ID

MODE

R N D

INDICATOR (LED)

Push simultaneously to enter diagnostic mode and fluid level check (optional)

PUSHBUTTON

SELECTOR

✽

NOTE:

Number displayed is highest forward range available in selected position. Visually check to confirm range selected. If display is flashing – shift is inhibited.

✽

213DNR

N R

STRIP PUSHBUTTON

SHIFT SELECTORS

V03496.02

Figure 2–1. Typical Shift Selectors

Information is displayed immediately if the two minute time period elapsed before a ﬂuid level data request was made. However, if the two minute period has not elapsed, there will be a countdown display before ﬂuid level information displays. The countdown display ﬂashes constantly. Countdown starts at 8 and decreases sequentially to 1 during the two minute period. When ﬂuid level data is requested, and the two minute countdown is in process, the ﬂashing display shows the number corresponding to the countdown progress.

For example:

• If the ﬂuid level data was requested in the middle of the two minute

countdown period, the display would ﬂasha5ora4anddecrease to 1.

• Shift Selector Display. Fluid level information is displayed one character at

a time as in Table 2–1:

Table 2–1. Fluid Level Shift Selector Display

Display Sequence Interpretation of Display

o L o K Fluid level is correct o L L o 1 Fluid level is 1 quart low o L H I 1 Fluid level is 1 quart high

The shift selector display will also show “invalid for display” codes one character at a time. An “invalid for display” code is returned when ﬂuid level data is requested, but an operational condition has not been met. The “invalid for display” condition interrupts the two minute countdown (momentary increase in engine speed does not affect the countdown). The “invalid for display” codes and their meaning are:

Table 2–2. Invalid For Display Codes

Display Sequence Interpretation of Display

o L – 5 0 Engine rpm too low o L – 5 9 Engine rpm too high oL –6 5 N (Neutral) not selected o L – 7 0 Sump ﬂuid temperature too low o L – 7 9 Sump ﬂuid temperature too high o L – 8 9 Output shaft rotation o L – 9 5 Sensor failure

NOTE: Report sensor failure to a distributor or dealer in your area. Consult the telephone directory for the Allison Transmission distributor or dealer near you.

The countdown is restarted when the condition causing the “invalid for display” code 59 has been corrected. The countdown is not restarted if there is a momentary increase in engine rpm which may generate a code 59. “Invalid for display” messages are as follows:

• Allison DOC™ Display. “Invalid for display” messages are displayed in the Oil (±) ﬁeld of the Data Monitor.

Allison DOC™ Message

OL — SETTLING TIME X OL — ENGINE SPEED LO OL — ENGINE SPEED HI OL — SELECT N (NEUTRAL) OL — SUMP TEMP LO

Allison DOC™ Message

OL — SUMP TEMP HI OL — OUTPUT SPEED HI OL — CHECK CODES

• Exiting the Fluid Level Mode. Exit as follows:

— For a pushbutton shift selector, press the N (Neutral) pushbutton once. — For a lever selector, press the DISPLAY MODE/DIAGNOSTIC

button once or move the lever to a range position.

— Allison DOC™ does not use a special Fluid Level Mode.

b. Manual Fluid Test Procedure.

WARNING: To help avoid personal injury or property damage caused

by sudden and unexpected vehicle movement, do not determine the ﬂuid level until you:

1. Put the transmission into N (Neutral).

2. Apply the parking brake and emergency brakes and make sure they are properly engaged.

3. Chock the wheels and take any other steps necessary to keep the vehicle from moving.

Clean all dirt from around the end of the ﬂuid ﬁll tube before removing the dipstick. Do not allow dirt or foreign matter to enter the transmission. Dirt or foreign matter in the hydraulic system may cause undue wear of transmission parts, make valves stick, and clog passages. Determine the ﬂuid level using the following procedure and report any abnormal ﬂuid levels to your service management.

c. Cold Test Procedure. The purpose of the cold test is to determine if the transmission has enough ﬂuid to be safely operated until a hot test can be made.

CAUTION: The ﬂuid level rises as ﬂuid temperature increases. DO NOT ﬁll above the “COLD CHECK” band if the transmission ﬂuid is below normal operating temperature. During operation, an over full transmission can become overheated, leading to transmission damage.

1. Park the vehicle on a level surface. Apply the parking brake and chock the wheels.

2. Run the engine for at least one minute. Shift to D (Drive), then to N (Neutral), and then to R (Reverse) to ﬁll the hydraulic system.

3. Shift to N (Neutral) and allow the engine to idle (500–800 rpm).

+ 58 hidden pages

Allison Transmission HD4060 Service Manual

TABLE OF CONTENTS

TRADEMARK USAGE

WARNINGS, CAUTIONS, NOTES

INTRODUCTION Section I

1–1. ABOUT THIS MANUAL

Figure 1–2. 3000 Product Family Transmission—Cross Section

Figure 1–6. 3000 Product Family Transmission with PTO

Figure 1–7. 3000 Product Family Transmission with Retarder

Figure 1–10. 4000 Product Family Transmission with PTO

Figure 1–11. 4000 Product Family Transmission with Retarder and PTO

2–1. PERIODIC INSPECTION AND CARE

2–2. IMPORTANCE OF PROPER TRANSMISSION FLUID LEVEL

2–3. TRANSMISSION FLUID TEST

Figure 2–1. Typical Shift Selectors

Table 2–1. Fluid Level Shift Selector Display

Table 2–2. Invalid For Display Codes