Allison Transmission 3000 Istruzioni per il montaggio
MT3004EN
Mechanic’s Tips
3000 and 4000
Product Families
Allison Transmission
Allison WTEC III Controls
(Except 3000 Product Family 7-Speed)
Mechanic’s
Tips
2006 MARCH
MT3004EN
3000 Product Family
4000 Product Family
Printed in USA Copyright © 2007 Allison Transmission, Inc.
Allison Transmission, Inc.
P.O. Box 894 Indianapolis, Indiana 46206-0894
www.allisontransmission.com
2
NOTES
TABLE OF CONTENTS
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
3
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
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.
•LPS Electro Contact Cleaner
®
is a registered trademark of LPS
Laboratories.
5
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.
6
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.
INTRODUCTION Section I
7
V03350.08.00
OIL LEVEL SENSOR
P2 MODULE
P1 MODULE
CONVERTER MODULE
• TURBINE
• PUMP
• LOCKUP
CLUTCH/DAMPER
• STATOR
CONVERTER HOUSING MODULE
• CONVERTER HOUSING
• PTO DRIVE GEAR ROTATING CLUTCH MODULE
• C1 CLUTCH
• C2 CLUTCH
• TURBINE SHAFT
CONTROL MODULE
• ELECTRO-HYDRAULIC
CONTROLS
MAIN SHAFT MODULE
• MAIN SHAFT
• P2 SUN
• P3 SUN
MAIN HOUSING MODULE
• MAIN HOUSING
• C3 CLUTCH
• C4 CLUTCH
• C5 CLUTCH
FRONT SUPPORT/OIL PUMP MODULE
• FRONT SUPPORT
• OIL PUMP
REAR COVER MODULE
• OUTPUT SHAFT
• P3
• C5 PISTON
Figure 1–1. 3000 Product Family Transmission
with PTO—Cross Section
8
ROTATING CLUTCH MODULE
C1 CLUTCH
C2 CLUTCH
TURBINE SHAFT
CONTROL MODULE
ELECTRO-HYDRAULIC CONTROLS
P1 MODULE
P2 MODULE
MAIN HOUSING MODULE
MAIN HOUSING
C3 CLUTCH
C4 CLUTCH
C5 CLUTCH MAIN SHAFT MODULE
MAIN SHAFT
P2 SUN
P3 SUN
REAR COVER MODULE
OUTPUT SHAFT
P3 MODULE
C5 PISTON
V07286.02.00
CONVERTER MODULE
TURBINE
PUMP
STATOR
LOCKUP
CLUTCH/DAMPER
CONVERTER HOUSING MODULE
CONVERTER HOUSING
FRONT SUPPORT/OIL PUMP MODULE
FRONT SUPPORT
OIL PUMP
Figure 1–2. 3000 Product Family Transmission—Cross Section
9
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