Mechanics TipsHT, HTB, CLT, CLBT 700 Series

Electronic Control Transmissions

MT1958EN

i

MT1958EN

Mechanics Tips

Allison Transmission

HT, HTB, CLT, CLBT 700 Series

March, 1995Revision 1, 1999 April

Printed in U.S.A. Copyright 1995 General Motors Corp.

Division of General Motors CorporationP.O. Box 894 Indianapolis, Indiana 46206-0894

ii

WARNINGS, CAUTIONS, AND 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. 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 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 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.

Three types of headings are used in this manual to attract your attention. These warnings and cautions advise of specific methods or actions that can result in personal injury, damage to the equipment, or cause the equipment to become unsafe.

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

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.

TABLE OF CONTENTS

Paragraph Description Page

SECTION I PREV

11. Period12. Import13. Transm14. Keepin15. Autom16. Transm17. Fluid T18. High-E19. Transm110. Transm111. Auxilia112. Breath113. Transm

SECTION II REMO

21. Drainin22. Discon23. Uncou24. Remov25. Remov26. Rebuil

SECTION III PREPFOR I

31. Checki32. Installi

(Remo33. Installi34. Installi35. CheckiENTIVE MAINTENANCEic Inspection and Care . . . . . . . . . . . . . . . . . . . . . . . . . . . 1ance of Proper Transmission Fluid Level . . . . . . . . . . . . 1ission Fluid Check Procedures. . . . . . . . . . . . . . . . . . . . 2g Transmission Fluid Clean . . . . . . . . . . . . . . . . . . . . . . 5atic Transmission Fluid Recommendations . . . . . . . . . . 5ission Fluid and Filter Change Intervals . . . . . . . . . . . . 6emperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7fficiency, Main-Pressure External Filter Change . . . . . . 8ission Fluid Contamination . . . . . . . . . . . . . . . . . . . . . . 8ission Fluid and Filter Change Procedure . . . . . . . . . . . 9ry Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

er . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10ission Stall Test and Neutral Cool-Down Check . . . . . . 10

VING TRANSMISSION FROM VEHICLEg Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13necting Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13pling From Driveline, Engine, and Vehicle. . . . . . . . . . . 14ing the Transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . 14ing Input and Output Flanges or Yokes . . . . . . . . . . . . . 14d, Overhaul Instructions . . . . . . . . . . . . . . . . . . . . . . . . . 15

ARING THE TRANSMISSIONNSTALLATIONng Input Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 16ng Output Flange and Input Flangete-Mounted Transmission) . . . . . . . . . . . . . . . . . . . . . . . 16ng PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17ng Transmission Fill Tube and Seal . . . . . . . . . . . . . . . . 18ng Plugs, Openings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18iii

Paragraph Description Page

SECTION IV PREPAINSTA

41. Engine42. Checki43. Checki

(Remo44. Chassi45. Cooler46. Checki

SECTION V INSTA

51. Handli52. Mount53. Installi54. Coupli55. Coupli56. Conne57. Conne58. Conne59. Conne510. Conne511. Installi512. Conne513. Installi

Conne514. Filling

SECTION VI CHECK

61. Installa62. Road T

SECTION VII CUST

71. Owner72. ServiceRING VEHICLE FOR TRANSMISSION LLATION , Transmission Adaptation Requirements. . . . . . . . . . . . 19ng Flexplate Drive Assembly . . . . . . . . . . . . . . . . . . . . . 20ng Input Drive Components te-Mounted Transmissions). . . . . . . . . . . . . . . . . . . . . . . 20s and Driveline Inspection . . . . . . . . . . . . . . . . . . . . . . . . 22, Filter, and Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22ng Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

LLING TRANSMISSION INTO VEHICLEng. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27ing to Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27ng Transmission Mounting Components . . . . . . . . . . . . 28ng to Driveline. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28ng to Engine (Remote-Mounted Transmission) . . . . . . . 28cting Input Retarder Control . . . . . . . . . . . . . . . . . . . . . . 29cting Output Retarder Control . . . . . . . . . . . . . . . . . . . . . 29cting Power Takeoff Controls . . . . . . . . . . . . . . . . . . . . . 29cting Parking Brake Control . . . . . . . . . . . . . . . . . . . . . . 30cting Cooler, Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30ng Auxiliary Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30cting Speedometer Drive . . . . . . . . . . . . . . . . . . . . . . . . . 30ng Temperature and Pressure Sensors,cting Electrical Components . . . . . . . . . . . . . . . . . . . . . . 32 the Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

S AND ADJUSTMENTStion Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33est and Vehicle Operation Checklist . . . . . . . . . . . . . . . 35

OMER SERVICE Assistance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Literature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39iv

PREFACE

This handbook is a mechanics reference for removing, installing, and maintainingthe HT, HTB, CL(B)T 700 Commercial Electronic Control Series AutomaticTransmissions. All features of the transmission and vehicle involved in installation procedures are discussed. The information presented will help the mechanic toremove, install, and maintain the transmission in a manner that assures satisfactory operation and long service life. For additional detailed information, refer to HT, HTB 700 Electronic Control Series Service Manual SM2004EN or CL(B)T 700 Series Service Manual SM1314EN and CL(B)T 755 Electronic Control Series Service Manual Supplement SM1992EN. Troubleshooting the electronic control system is presented in Troubleshooting Manual TS2712EN.

TRADEMARKS USED

DEXRON

is a registered trademark of General Motor Corporation.

Loctite

is a registered trademark of the Loctite Corporation.

Teflon

is a registered trademark of the DuPont Corporation.

Pro-Link

is a registered trademark of Micro Processor Systems, Inc.v

Model HT

Model HT

FROM FILTER

TO FILTER

FLYWHEEL BOLTACCESS COVER

CONVERTERHOUSING

BULKHEACONNECTO

NAMEPLATE

TRANSMISSIONMAIN CASE

PREHEAT PROVISION

REVERSE SIGNALSWITCH PORT

TRANSMISSION FLUIDFILLER TUBE PROVISION 741, 748 Transmission Left-Rear View

741, 748 Transmission Right-Front View

REAR COVERMOUNTING PAD

CONVERTER-DRIVENPTO ACCESS COVER

PARKING BRAKEMOUNTING PAD

OUTPUTSHAFT

SPEED SENSORPICKUP

TRANSMISSION FLUIDDRAIN PLUG

DR

H01932

TEMPERATURESENSOR PORT

TO COOLER

FROM COOLER

CONVERTER HOUSINGMOUNTING PAD

TORQUECONVERTER

STARTERRING GEAR

BREATHER

H01933vi

Model H

Model HT

FROM FILTER

TO FILTER

FLYWHEEL BOLTACCESS COVER

CONVERTERHOUSING

BULKHECONNECT

NAMEPLATE

TRANSMISSIONMAIN CASE

B

PREHEAT PROVISION

REVERSE SIGNALPORT

TRANSMISSION FLUIDFILLER TUBE PROVISIONT 755CR Transmission Left-Rear View

755CR Transmission Right-Front View

REAR COVERMOUNTING PAD

ADAPTER HOUSING

CONVERTER-DRIVENPTO ACCESS COVER

PARKING BRAKEMOUNTING PAD

OUTPUTSHAFT

SPEED SENSORPICKUP

TRANSMISSION FLUIDDRAIN PLUG

ADOR

H01934

TEMPERATURESENSOR PORT

TO COOLER

FROM COOLER

CONVERTER HOUSINGMOUNTING PAD

TORQUECONVERTER

STARTERRING GEAR

REATHER

H01935vii

Model HT 755DR Tr

Model HT 755DR Tra

FROM FILTER

TO FILTER

ENGINE-DRIVEN TOPPTO ACCESS COVER

CONVERTERHOUSING

ENGINE-DRIVENLEFT SIDE PTOACCESS COVER

BULKHEADCONNECTOR

TEMPERATURESENSOR PORT

NAMEPLATE

TRANSMISSIONMAIN CASE

PREHEAT PROVISION

REVERSE SIGNALPORT

TRANSMISSION FLUIDFILLER TUBE PROVISIONansmission Left-Rear View (With Input Retarder)

nsmission Right-Front View (With Input Retarder)

REAR COVERMOUNTING PAD

ADAPTER HOUSING

INPUT RETARDER BRAKE OPTIONCONVERTER-DRIVEN PTOACCESS COVER

PARKING BRAKEMOUNTING PAD

OUTPUTSHAFT

SPEED SENSORPICKUP

TRANSMISSION FLUIDDRAIN PLUG

H01936

TO COOLERFROM COOLER

INPUT RETARDERVALVE BODY

CONVERTER HOUSINGMOUNTING PAD

TORQUECONVERTER

STARTER RINGGEAR

FLYWHEEL

BREATHER

H01937viii

Model HTB 748 Tran

Model HTB 748 Tran

CONVERTERHOUSING

FLYWHEEL

FROM FILT

STARTERRING GEAR

RETARDER PISTONAPPLY LINE

SENSOR

RETARDERHOUSING

ACCUMULATOR

RETARDER VALVE BOD

REGULATOR VALVE BOsmission Left-Front View (With Output Retarder)

smission Right-Rear View (With Output Retarder)

PTO ACCESS COVER

ADAPTER HOUSING

GOVERNORCOVER

BULKHEADCONNECTOR

TO FILTER

ERH01938

RETARDER CONTROL AIR PRESSURE ADAPTER

FROM COOLER

TEMPERATURE PROBEPROVISION

TO COOLERNAMEPLATE

TO COOLER(CONVERTER-OUT)

LUBE PORT(FROM COOLER)

TRANSMISSION FLUIDFILLER TUBE PROVISIONY

DY H01939ix

x

Model CLBT 755 Transmission Left-Front View

Model CLBT 755 Transmission Right-Front View

CONVERTER-DRIVEN PTOACCESS COVER

MAIN HOUSING

MOUNTING PAD

BULKHEADCONNECTOR

8 1 2 in. CASTIRONOIL PAN

OUTPUTFLANGE NUT

SPEED SENSORPICKUP

CONVERTERINPUT DRIVE

CONVERTERACCESS COVER

FROM FILTER

INPUT RETARDER

H01940

INPUT RETARDERVALVE BODY

TO COOLER

FROM COOLER

FRONTMOUNTINGTRUNNION

NAMEPLATE

TRANSMISSIONMAIN CASE

BREATHER

REVERSE SIGNALPORT

TEMPERATURESENSOR PORT

H01941

11. PERIODIC INS

Clean and inspect the extservice and operating conInspect the transmission f

loose bolts tran

fluid leaks repa

loose, dirty, or imp

damaged or loose

worn, frayed, or im

worn or out-of-pha

A label describing on-vehAllison service dealer anin a vocation that requirehave an on-vehicle weldi

12. IMPORTANCE

Because the tpower, it is imIf the fluid lereceive an ad

will overheat. If the fluid lto shift erratically and ovedipstick tube when the flu

CAUTION

DO NOT

the ECU a

DO NOT

battery po

DO NOT

DO NOT

PREVENTIVE MAINTENANCE

SECTION I

PECTION AND CARE

erior of the transmission at regular intervals. Severity of ditions determine the frequency of these inspections. or:

smission and mounting componentsir immediatelyroperly adjusted throttle sensor linkage

hosesproperly routed electrical harnessesse driveline U-joints and slip fittings

icle welding precautions is available from your authorized d should be installed in a conspicuous place. A vehicle used s frequent modifications or repairs involving welding must ng label.

OF PROPER TRANSMISSION FLUID LEVEL

: When welding on the vehicle:WELD on the vehicle without disconnecting from ll control system wiring harness connectors.WELD on the vehicle without disconnecting ECU wer and ground leads.WELD on any control components.CONNECT welding cables to any control components.1

ransmission fluid cools, lubricates, and transmits hydraulic portant that the proper fluid level be maintained at all times.

vel is too low, the torque converter and clutches will not equate supply of transmission fluid, and the transmissionevel is too high, the fluid aerates causing the transmission rheat. Fluid may be expelled through the breather or id level is too high.

A severely low fluid levetwo things automatically

Turn on the CHEC

Prevent upshifting

When the fluid level is co

Do not use the Electroniclevel at the intervals spec

13. TRANSMISSIO

a.

Fluid Check Proced

Clean all dirdipstick. Dotransmissiontransmission

fluid level, manually, usimaintenance log. To perfidle speed and the transm

Add transmission fluid touse proper transmission fl15. Refer to Table 11 f

Tabl

WARNING

possible sudnecessary torunning, plaing brake an

Application

4

1

2

inch (114 mm) oil6 inch (152 mm) oil pa7 inch (178 mm) oil pa8

1

2

inch (215 mm) oil

NOTE: Does not include extl causes the Allison Transmission Electronic Control to do K TRANS light into the highest range

rrected, the transmission will return to normal operation.

Control to replace regular fluid level checks. Check the ified in your vehicle service instructions.

N FLUID CHECK PROCEDURES

ure.t from around the end of the fill tube before removing the not allow the dirt or any foreign matter to enter the . Dirt or foreign matter may cause undue wear of the parts, make valves stick, and clog passages. Check the

ng the following procedure and record the level in your orm the fluid level check, the engine must be running at ission must be in N (Neutral).

the transmission through the fill tube opening. Be sure to uid and fluid containers as discussed in Sections 14 and

or approximate transmission fluid capacity.

e 11. Transmission Fluid Capacity

: Take the following precautions so that unexpected,den vehicle movement is avoided. Whenever it becomes leave the vehicle, even momentarily, while the engine is ce the transmission shift selector in Neutral, set the park-d/or emergency brakes and chock the wheels.

U.S. Quarts Liters pan 34 32n 30 28.5n 30 28.5 pan 43 41ernal circuits.2

b.

Cold Check.

Park the vehicle onwheels.

Run the engine for

R

(Reverse) to clea

allow the engine to

Insert the dipstick Repeat the check p

If the fluid level isoperated until the flfluid level is not wbring it to the midd

Perform a hot chec160200F (7193

c.

Hot Check.

Operate the transm

reached:160200F (180220F (

Park the vehicle on

brake, and chock t

With the engine ru

Insert the dipstick the check procedur

NOTE: The purposhas enoughmade.

CAUTIONDO NOT filbelow norm

CAUTIONcheck. The fl a level surface. Apply the parking brake, and chock the

at least one minute. Shift to D (Drive) and then to r the hydraulic circuits of air. Then shift to N (Neutral) and idle (500800 rpm).into the tube and remove. Check the fluid level reading. rocedure to verify the reading.

within the COLD RUN band, the transmission may be uid is hot enough to perform a HOT RUN check. If the

ithin the COLD RUN band, add or drain as necessary to le of the COLD RUN band.k as soon as the normal operating temperature ofC) is reached.

ission in D (Drive) until normal operating temperature is

7193C) sump temperature82104C) converter-out temperature a level surface and shift to N (Neutral). Apply the parking

he wheels. Allow the engine to idle.nning, remove the dipstick from the tube and wipe it clean.into the tube and remove. Check fluid level reading. Repeat e to verify the reading.

e of the Cold Check is to determine if the transmission fluid to be safely operated until a hot check can be

:

The fluid level rises as fluid temperature increases. l above the COLD RUN band if the transmission fluid is al operating temperatures.

:

The transmission fluid must be hot to ensure an accurate uid level rises as temperature increases.3

If the fluid level is to bring the fluid le

d.

Consistency of Read

Always check the Consistency is impreading persists, chunclogged.

Fig

NOTE: Safe operatdipstick, Fi

HT/CTPAN SIZ

4.50"

6.00"

7.00"

8.50"

ApproximCOLD RU

not within the HOT RUN band, add or drain as necessary vel to within the HOT RUN band.

ings.fluid level at least twice and with the engine running. ortant to maintain accuracy of the reading. If inconsistent eck the transmission breather to be sure it is clean and

ure 11. Typical Dipstick Markings

ing level is within the HOT RUN band on the gure 11.

DIMAE

25.4 mm(1.00 IN.)38.1 mm(1.50 IN.)63.5 mm(2.50 IN.)63.5 mm(2.50 IN.)

ate Dimension, OEM/Customer is to establishN BAND at installation.

DIMB

38.1 mm(1.50 IN.)63.5 mm(2.50 IN.)88.9 mm(3.50 IN.)88.9 mm(3.50 IN.)

DIM C

50.8 mm(2.00 IN.)95.3 mm(3.75 IN.)120.7 mm(4.75 IN.)120.7 mm(4.75 IN.)

DIMD

44.5 mm(1.75 IN.)76.2 mm(3.00 IN.)

N/A

N/A

V01889

AB C

D

OIL PAN SPLIT LINE

HO

TR

UNCO

LDR

UN4

14. KEEPING TRANSMISSION FLUID CLEAN

Transmission fluid must foreign material from enremoving the dipstick. Ltransmission.

15. AUTOMATIC T

Hydraulic fluids (otransmission perfo

recommended for for severe-duty app

Some DEXRON

-

fluid is qualified fo

C-4 fluid license, omanufacturer. Consusing other fluid tyor may not be prop

When choosing thepreheat capabilitieconsideration. Tabtransmission may bequipment or by ru

minimum of 20 mi

CAUTION:

Containers or fillers that have been used for any anti-freeze or engine coolant solution must not be used for the transmis-sion fluid. Antifreeze and coolant solutions contain ethylene glycol which, if introduced into the transmission, can cause the clutch plates to fail.

CAUTION

result in tranbe handled in clean containers, fillers, etc., to prevent tering the transmission. Clean around the filler tube before ay the dipstick in a clean place while filling the

RANSMISSION FLUID RECOMMENDATIONS

ils) used in the transmission are important influences on rmance, reliability and durability. DEXRON-III fluid is light-duty applications. Type C-4 fluids are recommended lications.

III fluids are also qualified as Type C-4 fluids. To ensure the r use in Allison transmissions, check for a DEXRON-III or r approval numbers on the container, or consult the lubricant ult your Allison Transmission dealer or distributor before

pes; fluid types such as Type F, and universal farm fluids may erly qualified for use in your Allison transmission.

optimum viscosity grade of fluid to use, duty cycle, s, and/or geographical location must be taken into le 12 lists the minimum fluid temperatures at which the e safely operated. Preheat with auxiliary heating nning the vehicle with the transmission in N (Neutral) for a nutes before attempting range operation.

: Disregarding minimum fluid temperature limits can smission malfunction or reduced transmission life.5

Table 12. Operating Temperature Requirements for Transmission Fluid

16. TRANSMISSIO

a.

Frequency.

Transmissiontransmission general guideconditions cre

Table 13. Tr

b.

Abnormal Conditio

is evidence of dirt or a hiindicated by the transmisfluid analysis. Local condless frequent fluid or filte

Viscosity Grade

DEXRON

-IIISAE 10WSAE 15W-40SAE 30SAE 40

Ref. 13-TR-90.

Fluid Change Interval

50,000 miles (80 000 km)or 12 months or 1200 hours*

* Whichever occurs first.** An Allison high efficienc

contaminated or until it hrestrictions apply.N FLUID AND FILTER CHANGE INTERVALS

fluid and filter change frequency is determined by severity of service and by the filter equipment installed. Table 13 is a . More frequent changes may be required when operating ate high levels of contamination or overheating.

ansmission Fluid and Filter Change Intervals

ns. Transmission fluid must be changed whenever theregh temperature condition. A high temperature condition ission fluid being discolored or having a strong odor, or by itions, severity of operation, or duty cycle require more or r change intervals.

Ambient Temperature Below Which Preheat Is Required

Fahrenheit Celsius

17 274 20

5 1532 050 10

Internal Sump and Governor

Filter

Standard Main PressureExternal Filter**

At overhaul After first 5000 miles (8 000 km) and at each 25,000 miles (40 000 km) or 6 months or 600 hours, thereafter*

y filter may be used until the change filter light indicates it is as been in use for three years, whichever occurs first. No mileage 6

c.

Fluid Analysis.

Transmoptimized by monitoring flTable 14. Consult your teand accurate fluid analysisthe latest edition of GN20

Table 1

17. FLUID TEMPE

If the sensor is loccritical temperaturlocated in some ottemperatures. If thprocedure:

Stop the v

operate thetemperatu

If the transor if it convehicle an

Measuremen

ViscosityCarbonyl absorbanceTotal acid numberSolids

* Note: A = Absorbance unit

Co

Converter Operation

Retarder OperationLockup OperationNormal Operationission protection and fluid change intervals can beuid oxidation according to the tests and limits shown in the

lephone directory for fluid analysis firms. To ensure consistent , select only one fluid analysis firm. Refer to 55EN, Technicians Guide for Automatic Transmission Fluids.

4. Fluid Oxidation Measurement Limits

RATURES

ated in the converter housing or input retarder valve, the es are listed in the converter-out column. If the sensor is her area, refer to the vehicle manual for the critical e maximum fluid temperature is reached, follow this

ehicle and shift the transmission into N (Neutral) and engine at 1500 rpm to reduce the transmission fluid

re.mission fluid does not cool in approximately 30 seconds, tinues to overheat after operation is continued, stop the d engine and locate the problem.

Table 15. Fluid Temperatures

t Limit

25% change from new fluid+0.3 A*/0.1 mm change from new fluid+3.0 change from new fluid

2% by volume maximums.

ndition Converter-Out CLBT 700 Series HT 700 Series

275F (135C) max300F (149C) max

Intermittent 330F (166C) max250F (121C) max180220F (82105C)7

18. HIGH-EFFICIENCY, MAIN-PRESSURE EXTERNALFILTER CHANG

Allison high-efficiency exneed to be changed whenindicated. There is no mil

An Allison high-efficiencand transmission are at o

Filter

light is illuminated

changed for three years,

19. TRANSMISSIO

a.

Examine At Fluid Ch

that is drained for evidenemulsify in the fluid duridence of water, check thefluid areas. Fluid in the wleakage. This, however, m

b.

Metal Particles

.

Metal particles in the tranthe minute particles normthe transmission. When tbe disassembled and closrequire complete disasseexternal circuits, cooler, the repair of a major inteas many serviceable deta

disassemble the unit jus

c.

Coolant Leakage.

The presence of etdetrimental to the Ethylene glycol hanonmetallic composuch as bearings an

CAUTION

the cooler aE

ternal filters, which have a change filter indicator, do not the transmission fluid is changed unless restriction is eage limitation with the use of Allison high-efficiency filters.

y external filter element must be changed if the engine perating temperature (over 160F; 71C) and the Change for any length of time or the element has not been

whichever occurs first.

N FLUID CONTAMINATION

ange. At each transmission fluid change, examine the fluid ce of dirt or water. A normal amount of condensation will ng operation of the transmission. However, if there is evi- cooler (heat exchanger) for leakage between the water and ater side of the cooler (heat exchanger) is another sign of ay indicate leakage from the engine oil system.

smission fluid or on the magnetic drain plug (except for ally trapped in the filter) indicate damage has occurred in

hese particles are found in the sump, the transmission must ely inspected to find the source. Metal contamination will

mbly of the transmission and cleaning of all internal and and all other areas where the particles could lodge. During rnal failure of a transmission, it should be dismantled into il parts as possible and thoroughly cleaned. Do not t to the problem area.

hylene glycol coolant in the transmission fluid is reliability and durability of the internal components. s a deteriorating effect on friction-faced clutch plates and nents (seals, gasket, etc.) and on highly loaded steel parts, d gears, due to reduced lubricity of the fluid.

: If excessive metal contamination has occurred, replace nd all bearings within the transmission.8

d.

If the presence of ethylene glycol in the fluid is suspected, immediately perform a verification test. A Gly-determine the presence otransmission, and removecoolant contamination. RRepair or replace the coo

110. TRANSMISSIO

a.

Drain Fluid.

Drain the fluid wh160200F (7193

Remove the drain a suitable containe

Examine the fluid

b.

Replace Filters.

Refer to the latest for complete proce

Remove the oil pan

c.

Refill Transmission.

for the initial fill. Fluid reafter draining the transmdescribed in Section 13.

111. AUXILIARY FIL

If a condition occusystem, a complete

Because repeated cauxiliary filter in thin the lubrication crecommendation aby a new or rebuilt

If any doubt exists

NOTE: Do not drareplaced.Tek test kit is available and is a quick and easy method to f glycol. If glycol is found, disassemble and inspect the all traces of coolant and varnish deposits resulting from eplace all seals, gaskets, and friction-faced clutch plates. ler prior to installation of the new or rebuilt transmission.

N FLUID AND FILTER CHANGE PROCEDURE

en the transmission is at operating temperature C). Hot fluid flows quicker and drains thoroughly.plug from the oil pan and allow the fluid to drain intor.as described in the Section 18.

edition of the HT 700 Series Service Manual SM2004EN dures for replacement of the filter., and replace the old filter with the new one.

The amount of refill fluid is less than the amount usedmains in the external circuits and transmission cavities

ission. After refill, check the fluid level using the procedure

TERrs that introduces debris into the transmission hydraulic cleanup of the cooler and lines is required.leaning and flushing may not remove all debris, install an e cooler-out circuit (models without an output retarder), or ircuit (models with an output retarder). This pplies whether the transmission is overhauled or replaced unit. about the cleanup of the cooler, replace the cooler.

in the transmission fluid if only filters are being 9

The auxiliary filtermaximum filter pre180F (82C). The30 psi (207 kPa) at

D

(Drive) at full th

The following aux

112. BREATHER

a.

Location and Purpo

ing. The breather preventsage must be kept clean a

b.

Maintenance.

The amquency of breather cleanSPRAY STEAM, WATEBREATHER. Spraying scan force the water or cle

c.

Replacement.

Alwaysbreather. Pliers or a pipe wwhich could enter the tran

113. TRANSMISSIOCOOL-DOWN C

Table 1

Filter Assem

Allison 29510921*AC PM 13-16AC PM 16-1FX 11583Fram HP 1-1Purolator OF-15C-1Purolator 20-10

* High-efficiency filter and eRef: SIL 12-TR-93 (latest

WARNING

must be prevbrakes and bthe vehicle a must have at least a 40-micron filter element or finer and a ssure drop of 2 psi (14 kPa) at 15 gpm (57 liters/minute) at

maximum external circuit pressure drop must not exceed 15 gpm (57 liters/minute) at operating temperature, inrottle stall.iliary filters are recommended:

se. The breather is located on top of the transmission hous-s air pressure buildup within the transmission and its pas-nd open.

ount of dust and dirt encountered will determine the fre-ing. Use care when cleaning the transmission. DO NOT R, OR CLEANING SOLUTION DIRECTLY AT THE team, water, or cleaning solution directly at the breather aning solution into the transmission.

use a wrench of the proper size to remove or replace the rench can crush or damage the stem and produce metal chips smission. Tighten the breather to 912 lb ft (1216 Nm).

N STALL TEST AND NEUTRAL HECK

6. Auxiliary Filter Recommendations

bly Filter ElementAllison 29510918*PF 897PF141HF6520HP 1 or AC HD 222OF-2C-1PER-20

lement are available from your authorized Allison distributor. revision)

: When conducting a transmission stall test, the vehicle ented from moving. Apply the parking brake and service lock the vehicle securely. Warn personnel to keep clear of nd its travel path. Failure to do so can cause serious injury.10

a. Purpose.The stall tesis in the engsatisfactorily

The neutral cool-down chto gather transmission flu

b. Transmission Stall Tis compared to the engin

Connect a tachometemperature probetransmission to the

On the 755 Series tthe optional stall crange.

With the vehicle bengine at wide-opea minimum of 255

Reduce engine spe

NOTE:The enginestall test. Tmanufactu

CAUTIONrange. Do nfirst (low) gvehicle driv

CAUTIONseconds at atemperature(149C). Doduration. Dufaster than cnot let the et provides a method for determining if the malfunctionine or in the transmission when a vehicle is not performing .

eck utilizes the two-minute cooling period on the stall test id temperature data for troubleshooting reference.

est Procedure. The engine stall point (rpm) under loade manufacturers specified rpm for the stall test.

ter of known accuracy to the engine and install a into the converter-out (to cooler) line. Bring the normal operating temperature 160200F (7193C).

ransmissions, shift the selector to D (Drive) range or utilize heck feature. On the 741 or 748 Series, shift to any forward

locked, parking brake and service brake applied, hold the n throttle. When the converter-out temperature reachesF (124C), record the engine speed.ed to idle and shift to N (Neutral).

manufacturers test data must be available for the his data can be obtained from the engine rer, or from your equipment dealer or distributor.

: Do not attempt to stall test any transmission in reverse ot attempt to stall test the 755DR Series transmission in ear. The torque produced in that gear can damage the eline.

: Never maintain the stall condition for more than 30 ny one time because of the rapid rise in transmission fluid . Do not let the converter-out temperature exceed 300F not rely on converter-out temperature to limit stall ring stall conditions, internal temperatures rise much onverter-out temperature. If the stall test is repeated, do ngine overheat.11

c. Neutral Cool-Down Check Procedure. The neutral cool-down check determines if the transmission fluid cools following an engine load condition. Perform this check immediately after the engine speed has been recorded in the stall test.

Record the converter-out temperature. With the transmission remaining in Neutral, run the engine at 12001500 rpm

for two minutes to cool the transmission fluid. At the end of two minutes, record the converter-out temperature.

d. Results.

If engine stall speed is mengine manufacturer, an

If engine stall speed is mproblem is indicated, sucfailure. Refer to Section

An extremely low stall spduring which the engine

If the engine stall speed coverheats, refer to the coduring the two-minute co

If the engine stall speed cthat transmission fluid co

NOTE:Environmental conditions, such as ambient temperature, altitude, engine accesconverter. U150 rpm ofore than 150 rpm below the stall speed specified by the engine problem is indicated, such as need for tune-up.

ore than 150 rpm above specification, a transmission h as slipping clutches, cavitation, or torque converter 26 for the applicable service manual number.

eed, such as 33 percent of the specified engine stall rpm, does not smoke, could indicate a freewheeling stator.

onforms to specification, but the transmission fluid ol-down check. If the transmission fluid does not cool ol-down check, a stuck stator can be indicated.

onforms to specification and the cool-down check shows ols properly, refer to Troubleshooting Manual TS2712EN.

sory loss variations, etc., affect the power input to the nder such conditions, a stall speed deviation within specification can be accepted as within normal range.12

21. DRAINING TRA

Drain the transmission fl

Remove the drain fluid for evidence oplug.

Remove transmiss

Disconnect all othefrom the vehicle ifhose openings to k

22. DISCONNECTI

Disconnect or comremoved from the transmission remo

Disconnect the eleconnector and from

If an external pressharness from switc

Disconnect the spe Disconnect the air

retarder is used). Disconnect the inp

NOTE:A significanhydraulic liNSMISSION

uid before the transmission is removed from the vehicle.

plug from the oil pan. Examine the drained transmission f contamination (see Section 19). Reinstall the drain

ion fluid fill tube if it interferes with transmission removal.

r hydraulic lines from the transmission. Remove the lines they will interfere with the transmission removal. Plug all eep dirt from entering the hydraulic system.

NG CONTROLS

pletely remove the electronic controls. If controls are not transmission, position them so they do not interfere with val.ctronic control chassis harness from the transmission main the speed sensor connector (Figure 21).ure switch for a reverse signal is used, disconnect vehicle h.edometer drive cable, if used.

t amount of transmission fluid may drain from the nes when they are disconnected from the transmission.

SECTION II

REMOVING TRANSMISSION FROM VEHICLE13

supply line at the output retarder control valve (if output

ut retarder control linkage (if input retarder is used).

F23. UNCOUPLING

Disconneflange. Poremoving

If transmiother sup

Support the transmequipment.

Remove all bolts, ntransmission to the

24. REMOVING TH

Move theclear of th

Raise or lvehicle.

25. REMOVING IN

When replacing the transflanges or yokes to the reby a large self-locking nu

BULKHEADCONNECTORigure 21. Disconnect Locations

FROM DRIVELINE, ENGINE, AND VEHICLE

ct the vehicle driveline from the transmission output sition the disconnected shaft to avoid interference when the transmission.ssion mounts support the rear of the engine, place a jack or port under the engine.ission securely on a hoist, jack, or other suitable removal

uts, washers, spacers, and supports that attach the vehicle and to the engine (reference Figure 41).

E TRANSMISSION

transmission away from the engine until it is completely e engine. If used, remove the adapter ring and/or gasket.ower the transmission as necessary to remove it from the

PUT AND OUTPUT FLANGES OR YOKES

mission, it may be necessary to transfer input and output placement transmission. If the flanges or yokes are retained t, follow specific procedures below for removal of the nut.

SPEEDOMETERDRIVE OPENING

SPEEDSENSOR

L01498.0114

Before removing thinto the wrenchingaway.

If there are less thashaft thread. Then nut and flange.

Check the runningremoved (no notchEach additional timmust be at least 30running torque lim

26. REBUILD, OVE

Refer to the latest editionof the transmission:

HT, HTB 700 CL(B)T 700 S

Electronic Con

CAUTIONoutput nut rflange can ce self-locking nut, check to see if there are any notches cut flats. If there are five notches, remove the nut and throw it

n five notches or none at all, remove dirt and burrs from the loosen the nut until there is about 116 inch gap between the

torque as the nut is being removed. The first time the nut is es), running torque must be at least 400 lb in. (45 Nm). e the nut is removed (one to four notches), running torque

0 lb in. (34 Nm). Discard the nut if it does not meet the it.

RHAUL INSTRUCTIONS

of the following Service Manuals for rebuild or overhaul

Electronic Control Series Service Manual SM2004ENeries Service Manual SM1314EN, with CL(B)T 755 trol Series Service Manual Supplement SM1992EN

: The use of an impact wrench for removing the input or equires a means to hold the flange. Failure to hold the ause internal damage to the transmission.15

31. CHECKING INP

a. Bolt Holes. Check alladapter. The threads musforeign materials.

b. Pilot Boss. Check themetal which could preve

c. Starter Ring Gear. C

d. Transmission Mounraised metal, dirt, or piec

e. Transmission-To-Enmounting flange for raisethe threaded holes for da

32. INSTALLING O(REMOTE-MOU

a. Output Oil Seal. Chseal for leaks or damage.tronic Control Series Serual SM1314EN with CLSupplement SM1992ENtransmission fluid.

b. Check Yoke. Inspect tact surface must be smothe seal. Rotate the flang

c. Installing the Parkinbrake mounting pads on facturer specifications.

d. Installing Output Yo

SECTION IIIUT COMPONENTS

bolt holes on the front of the flywheel/converter/flexplate t be undamaged, and the holes must be free of any chips or

pilot boss (at center of flywheel) for damage or raised nt bolt free entry into the flex disk hub (adapter).heck the starter ring gear for excessive wear or damage.

ting Flange. Check the transmission mounting flange for es of gasket material.

gine Mounting Flange. Inspect the transmission-to-engine d metal, burrs, or pieces of gasket material. Also inspect maged threads.

UTPUT FLANGE AND INPUT FLANGENTED TRANSMISSION)

eck the output flange rear oil seal and input front flange oil Replacement instructions are in the HT, HTB 700 Elec-vice Manual SM2004EN, and CL(B)T Series Service Man-(B)T 755 Electronic Control Series Service Manual . Lubricate the oil seals with high-temperature grease or

each flange or yoke for damage or wear. The oil seal con-oth and regular to prevent transmission fluid leaking past

PREPARING THE TRANSMISSION FOR

INSTALLATION16

e during installation to avoid seal lip damage.

g Brake. Install the parking brake assembly on the parking the transmission, and tighten the bolts to the vehicle manu-

ke. Install the rear output yoke on the rear output shaft.

33. INSTALLING P

Access to the PTO mountransmission determine wtransmission is installed.

a. Install Guide Pins quired position of the guiguide pins must align witpins into the converter-ho

b. Determine the Backdriven PTO or an engine

For the turbine-dri(in the transmissio(0.460.60 mm) prafter S/N 32403 m

For the engine-driv(0.160.73 mm).

Refer to the latest of the method to dselecting proper th

c. Mount the PTO. Mogear with the PTO drive gInstall the remaining bol

CAUTIONPTO. Use ocatalog of y

NOTE:DO NOT uswith automa

CAUTIONthe PTO drisolenoid valTO

ting pads and the space available to maneuver the hether the PTO should be installed before or after the

Included in the PTO Installation Kit. Determine the re-de pins in relation to the mounted position of the PTO. The h the two blind holes in the PTO. Install two headless guide using PTO pad. Tighten the pins.

lash and Proper Gasket/Shim. You might have a turbine--driven PTO.ven PTO, the prescribed backlash between the drive gearn) and the driven gear (in the PTO) is 0.0180.024 inchior to S/N 32404, and 0.0060.029 inch (0.160.73 mm) odels.en PTO, the prescribed backlash is 0.0060.029 inch

edition of Service Manual SM2004EN for the description etermine the backlash. Establish proper backlash by ickness of shims (gaskets).unt the PTO on the guide pins, meshing the PTO driven ear. Retain the PTO by installing a bolt in the top bolt hole.

ts. Tighten the bolts to 5161 N.m (3845 lb ft).

: DO NOT use cork or other soft gaskets to install the nly the shims/gaskets listed in the appropriate parts our transmission model.

e sealing compounds they are usually incompatible tic transmission fluid.

: PTO units using transmission main pressure to engage ven gear must have a positive main pressure shut-off at the ve when the PTO is not engaged.17

34. INSTALLING T

a. Inspection. Inspect tha vent hole should be locthe dipstick, and the diam

b. Location. The filler tunused fill tube provisionopening.

c. Installation. Install tthrough the seal. Align thbolts and tighten to 141

35. CHECKING PL

Check carefully at all sidpressure check plugs.

The 18 inch pipe p Check the four ope

cleanliness. Remov Check the drain pl

lb ft (2127 Nm). Check the main ele

cleanliness.

CAUTIONToo long a bto the appro700 Series PRANSMISSION FILL TUBE AND SEAL

e fill tube for proper vent location and vent hole diameter; ated on the underside of the tube and just below the seal of eter should measure 0.0600.080 inch (1.62.0 mm).

ube may be mounted on either the left or the right side. The must have an expansion plug installed in the fill tube

he fill tube into the main housing. Insert the fill tube e tube bracket with its bolt location. Install the fill tube 8 lb ft (1924 Nm).

UGS, OPENINGS

es of the transmission for loose or missing hydraulic

lugs should be tightened to 4860 lb in. (5.56.7 Nm).nings into which the cooler and filter lines connect, for e any closures or obstructions.

ug for tightness. The drain plug must be tightened to 1520

ctrical connector in the transmission housing for

: Install the fill tube brackets with the correct length bolt. olt may cause cracks and leaks in the main housing. Refer priate HTB 700 Series Parts Catalog PC1965EN or CLT arts Catalog PC1993EN.18

41. ENGINE, TRAN

You must ensure that a neengine. The explained meengine adaptation. Refer

a. Measuring Equipmeequipment.

24.0 inches (600 m 24 inches (50100 13 inches (2576 06 inches (0150 Dial indicator and

b. Flywheel Housing Piter must measure from 20

c. Flywheel Housing Bo0.020 inch (0.51 mm) TIRd. Flywheel Housing Faout-of-square more than 0

e. Crankshaft Hub Piloadapter pilot diameter mu

f. Crankshaft Hub Piloer cannot be out-of-squar

g. Crankshaft Hub Pilohub adapter cannot be ou

h. Flexplate Bolt Hole Fa measurement required f

i. Torque Converter Axmeasure from the torque cmounting face. The torque(91.2486.69 mm).SMISSION ADAPTATION REQUIREMENTS

w transmission installation can be adapted to the vehicles asurements in this section ensure correct transmission-to-

to Figures 41, 42, and 43.

nt. Refer to the following list for the required measuring

m) precision caliper mm) telescoping gaugemm) outside micrometermm) depth micrometermounting attachments base, posts, and clamps

lot Bore Diameter. The flywheel housing pilot bore diame-.12520.130 inches (511.18511.30 mm).re Runout. Flywheel housing bore runout cannot exceed .

ce Squareness. The flywheel housing face cannot be.020 inch (0.51 mm) TIR. t or Adapter Diameter. The crankshaft hub pilot or hub st measure between 2.4372.439 inches (61.9061.95 mm). t or Adapter Squareness. The crankshaft hub or hub adapt-e more than 0.005 inch (0.13 mm) TIR.t or Adapter Eccentricity. The crank shaft hub pilot or the

SECTION IV

PREPARING VEHICLE FOR TRANSMISSION

INSTALLATION19

t-of-square more than 0.005 inch (0.13 mm) TIR.latness. Flexplate flatness in the area of the bolt holes is not

or HT and CT 700 Series flexplates.

ial Location. Refer to Figure 42. Using a depth gauge,onverter housing to the torque converters flexplate adapter converter axial location should measure 3.5923.413 inches

42. CHECKING FLE

a. Flexplate Inspectiongated bolt holes. Replaceb. Engine Crankshaft Eengine manufacturers spc. Flexplate Assembly Ihub using the bolts and t

43. CHECKING INP(REMOTE-MOU

Inspect shaft condisound.

Remove any accum Inspect universal j

wear or damage. Lubricate universa

recommended lubr

Figure 41. Typi

NOTE: Misindexin

CRANKSHAFT

DRIVE BOLT

STARTER RING GEXPLATE DRIVE ASSEMBLY

. Inspect the flexplate for cracks, wear, distortion, and elon- a damaged part.nd Play. Ensure that the crankshaft end play is within the

ecifications.nstallation. Install the flexplate onto the engine crankshaft

orque values specified for that engine.

UT DRIVE COMPONENTS NTED TRANSMISSIONS)

tion. The shaft must not be dented or bent. Welds must be

ulation of grease and dirt.oints, yokes, coupling flanges, and slip-joint splines for

l joints and slip-joints using the vehicle manufacturers icants.

cal Method Of Coupling Transmission To Engine

g of driveline can cause failure of the transmission.

ADAPTER-TO-CRANKSHAFT BOLT

FLEXPLATE ASSEMBLY

FLYWHEEL

3.554 in. (90.27 mm)3.451 in. (87.67 mm)

INNER WEAR PLATE

FLYWHEEL HOUSINGCONVERTER HOUSING

(12)

AR

CRANKSHAFT HUB ADAPTERFLEXPLATE-TO-ADAPTER BOLT

L01499.0120

Figure 4

Figure 43

FLEXPLATEASSEMBLY

ENGINE

FLYWHEELHOUSING2. Converter Axial Location Measurement

. Arrangement of Adaptation Components

V01717

CRANKSHAFTHUB ADAPTER

WEARPLATE

STARTERRING GEAR

TRANSMISSION

FLEXPLATEADAPTER

L0276421

44. CHASSIS AND

Inspect the chassis and drcorrect them as appropria

Transmission mou Bolts and other ha Isolators (rubber m Driveline angles

manufacturers rec Driveline yoke slip

freedom of mo damaged or w correctly lubri correctly index

Driveline midship Universal joints:

freedom of mo damaged or w correctly lubri correctly index

Vehicle differentia Universal joint cou Cross-frame memb PTO driven equipm Auxiliary transmis

shaft alignmen alignment of y backlash fluid leaks

45. COOLER, FILT

a. Inspection. Perform Transmission fluid

Check for con Inspect for det Inspect for fau Clean and flus

Pressure check DRIVELINE INSPECTION

iveline components for the following conditions, and te.

nts broken or worn-outrdware damaged, missing, or incorrectounts) damaged or missing runout, balance, or offsets which do not conform to the

ommendations joints: vement

orn-outcateded

or hanger bearings damaged or misaligned

vementorn-outcateded

l backlash manufacturers specificationpling alignment and differential damageers and rear support members condition and location ent shafts and couplings damaged or misaligned

sion:toke or flange

ER, AND LINES

the following and correct any faulty conditions: cooler and related coolant lines:tamination clean and flush as necessaryeriorationlty connectors or kinksh transmission fluid cooler, both coolant and oil sides. both sides using a 40 psi (276 kPa) air supply.22

Hydraulic lines: Check for con Inspect for det Inspect for fau

b. After Overhaul. A cohaul cannot be assumed. from the transmission flu(lube) filter after 5000 mlevel refer to Paragrap

46. CHECKING CO

a. Inspection. Inspect thconditions:

Shift selector: proper operati proper electric proper harness

Speedometer drive wear

damage kinks lubrication proper routing

Cab and chassis w proper connec frayed insulati wiring damage

Throttle sensor com freedom of mo improper routi bellows damag improper or lo

Throttle sensor adj accuracy

Parking brake cont cracks bends damaged threa clevis pins worn-out rod etamination clean and flush as necessaryeriorationlty connectors, or kinks

mplete cleanup of the transmission system after an over-Repeated cleaning and flushing may not remove all debris id cooler system. Replace the transmission from cooler iles (8000 km). Refill the transmission to the correct fluid h 14.

NTROLS

e following control components and correct any faulty

onal connection routing cable:

iring harness:tionson

ponents:vementngeose cable mountingustment:

rols:

ds

nds

23

Hydraulic retarder damage wear

frayed cable worn-out rod e cotter pins lubrication proper operati

PTO control: damage wear

improper oper lubrication

Temperature gauge capillary tube sensor damage

Fluid pressure gau damage kinks improper routi

b. Throttle Position Seequipment manufacturer,necessary, confirm that itcalibrating, and thereforeIdle count should be 50 othe counts are in the 50 anclosed and full throttle, t

c. Hitch-Pin Throttle P Install the throttle

Clamp cable e Secure the sen Install a heat s

manifold, turb Adjust the Hitch-P

The engine fu Install the hit

with bracketsinch (1117 mthrottle positithe idle positi control:

nds

on

ation

:damage (if used)

ge tubing:

ng

nsor (TPS) Adjustment When properly installed by the the TPS should not need adjustment. If TPS adjustment is has been installed to ATD specifications. The TPS is self- has no optimum close throttle or full throttle count value. r higher and full throttle should be 200 or lower. As long as d 200 range, with a difference of 85 to 130 counts between

he TPS is set correctly. Refer to Figure 44.

osition Sensor Installation. Refer to Figure 45.sensor body as follows:nd, using clamp and shims sor body, using the mounting holes provided.hield if any part of the throttle sensor is near the exhaust ocharger, or any other heat source.in throttle sensor as follows:el lever must be at the closed throttle position.ch-pin cable end of the sensor to the engine fuel lever so that at the idle position, the cable end is 0.440.67 m) from its fully retracted position, and at wide open

on, the cable end is 0.600.90 inch (1522.9 mm) from on.24

Figure 44

Check the stroopen. Stroke d

Recheck for z0.600.90 inch

Design throttleso that the syst

d. Slip-Link Throttle S Loosen 1420 nuts

retracted position. Make sure the eng Tighten nut A agai

inch (11.216.7 mmclearance betweenslip-link. Then tigh

Recheck for zero c(11.216.7 mm) di

Move the throttle fthrottle sensor. The(16.021.8 mm).

255 COUNT

FULLYRETRACTED

233 COUNTS

0.2 INCH0

APPROX.0.5 INCH

ERROR

ZONE. Throttle Position Determination Diagram

ke distance of the throttle sensor, from closed to wideistance must be from 0.600.90 inch (1522.9 mm).ero clearance at the fuel lever. Make sure that the (1522.9 mm) dimension has not changed. sensor linkage brackets and levers to nominal dimensionsem stays within tolerance band throughout its operating life.ensor Installation. Refer to Figure 46. A and B enough to let the threaded shaft move to its fully

ine fuel lever is at the closed throttle position.nst the slip-link until the threaded shaft moves 0.440.66

) from its retracted position. Check to be sure there is zero the drive pin on the fuel lever and the end of the slot in the ten nut B securely against the slip-link.learance at the fuel lever. Then recheck the 0.440.66 inch mension to ensure that it has not changed.rom closed to wide open to check the stroke distance of the stroke distance must be within the range of 0.630.86 inch

0 COUNT

FULLYEXTENDED

14 COUNTS

IDLEFULL

THROTTLE1.8 INCHES 1.9 INCHES

ERROR

ZONE

APPROX.0.75 INCHSTROKE

V0194225

Figure 45. H

Figure 46.

Attach to engine using clamp and must positively lo

FULLY

3.(87

CLOSE

H

Fuel lever attachment linallow fuel lever to re

position even when sena

THREADED SH

NUT

N

BELLOWS

FULLY RETRACTitch-Pin Throttle Sensor Installation Diagram

Slip-Link Throttle Sensor Installation Diagram

V01501

ENGINE FUEL LEVER

BELLOWS

FULLY EXTENDED

or governor housingshims as required. Clampck in cable groove.

RETRACTED

0.630.86 IN.(16.021.8 mm)

4313.679 IN..1593.44 mm)

0.440.66 IN.(11.216.7 mm)

1.861.88 IN.(47.347.7 mm)

FULL THROTTLED THROTTLE

ITCH-PIN CLIP

kage or bracket mustturn to closed throttlesor rod is maintainedt full throttle position.

V01500

FULLTHROTTLE

CLOSEDTHROTTLE

0.630.86 IN.(16.021.8 mm)

ENGINE FUELLEVER

AFT

BUT A

0.440.66 IN.(11.216.7 mm)

SLIP LINK

ED POSITION26

51. HANDLING

a. Preventing Damagecomponents in the install

b. Control of Transmislows precise control of tr

52. MOUNTING TO

Align oneopening a

Install a hflywheel the access

Lubricate the cente Push the transmiss

flywheel into the flthe flexplate.

Seat the transmissiis required if infrom the engine an

Align the bolt holehousing. Install allengine.

Tighten four bolts circle. Then tightevehicle or engine m

CAUTIONflywheel hoseat the hou. Carefully handle the transmission to prevent damage to ation path.

sion Movements. Use a hoist or transmission jack that al-ansmission movement during installation.

ENGINE

of the flexplates bolt holes in the flexplate with the access t the front of the engine flywheel housing.eadless guide bolt into one of the flexplate bolt holes in the (Figure 41). Align the guide bolt with the flexplate hole at opening.r pilot boss with molybdenum disulfide grease.ion toward the engine while guiding the pilot boss on the explate hub (adapter), and the guide bolt into the hole in

on squarely against the engine flywheel housing. No force terference is encountered, move the transmission away d investigate the cause.s in the converter housing with those in the engine flywheel of the bolts, finger tight, that retain the transmission to the

: The converter housing must be flush against the engine using before tightening any bolts. Do not use the bolts to

INSTALLING TRANSMISSIONINTO VEHICLE

SECTION V27

at 90 degree intervals around the converter housing bolt n the remaining bolts. Use the torque recommended by the

anufacturer.

sing.

Remove the guide housing. Replace ifinger tight at this

Rotate the engine dinch self-locking btwelve 1220 x 34 lb ft (131155 Nm

Install the flywhee

53. INSTALLING T

Install all bolts, wasupport the transm

Tighten the bolts to

54. COUPLING TO

Couple the drivelinyoke on the transmvehicle manufactu

Check the universathey are within the

55. COUPLING TO

Install (if removedand transmission.

Couple the flange transmission. Use manufacturer.

Check the transmismanufacturers spe

NOTE: Do not tighteinstalled and

CAUTIONby the vehicbolt through the access opening in the engine flywheel t with a 1220 x 1 inch self-locking bolt. Tighten the bolt time.

rive shaft enough to install the eleven remaining 1220 x 1 olts into the flywheel, finger tight. When all bolts including inch self-locking bolts are in place, tighten them to 96115 ).

l housing access cover.

RANSMISSION MOUNTING COMPONENTS

shers, spacers, isolators, brackets, and supports required to ission in the vehicle frame.

the torque recommended by the vehicle manufacturer.

DRIVELINE

e companion flange or universal joint yoke to the flange or ission. Use the bolts and torque recommended by the

rer.l joint angularity (all joints in driveline) to determine if specifications of the vehicle manufacturer.

ENGINE (REMOTE-MOUNTED TRANSMISSION)

) the input drive shaft components that connect the engine

or yoke to the flange or yoke at the front of the the bolts and torque recommended by the vehicle

sion to engine alignment against the vehicle cifications.

n any flywheel bolts until all of the bolts have been tightened finger tight.

: Use the type and grade of mounting bolts recommended le manufacturer.28

56. CONNECTING

Place the operator Check the input re

into the valve bodyposition, to check position.

Release the valve, is fully retracted.

Adjust the linkageretarder valve. Conoperation of the vacontrol is at ON.

The valve must be

57. CONNECTING

The output retarder (whesupply line.

Connect the air supfitting to 710 lb ft

58. CONNECTING

If not previously inParagraph 33 for

Connect controls t Check cable or lin

of the cable to exhmust not rub or int

Couple the PTO oujoints for proper as

NOTE: Failure to entransmissionresult in less

CAUTIONPTO must hwhen not inINPUT RETARDER CONTROL

s control at the OFF (disengaged) position.tarder control valve. The valve is spring-loaded to retract when the retarder is OFF. Lift the valve upward, to the ON for the full travel of 1.5 inches (38 mm) from OFF to ON

permitting the spring to retract the valve. Be sure the valve

so that rod end or clevis registers with the pin hole in the nect the linkage to the retarder valve and check the lve. The valve must be fully extended when the operators

fully retracted when the control is at OFF.

OUTPUT RETARDER CONTROL

n used) is connected to the vehicle braking system by an air

ply hose fitting to the retarder control valve. Tighten the (1013 Nm).

POWER TAKEOFF CONTROLS

stalled, mount the PTO on the transmission. Refer to instructions.o the PTO. Check for proper operation of the controls.kage rod routing. Kinks, sharp bends, and close proximity aust pipes or manifold must be avoided. Rods or linkage erfere with adjacent parts.

tput to its driven equipment. Check couplings or universal sembly and alignment.

sure a full off stroke will result in low vehicle power and overheating. Failure to ensure a full on stroke will than rated retarder performance.

: PTOs using main transmission oil pressure to apply the ave main pressure dead-headed at the PTO control valve use.29

59. CONNECTING

Connect and prope Adjust the brake sh

510. CONNECTING

Figure 51 shows typical

Be sure that the hyUse new O-ring se

Secure the filler tu Connect the hydra

filter, checking to s Tighten the line fit

Figure 51. Check for sharp be

chafe or collapse t Check to ensure th

manifolds or exhauhydraulic lines.

511. INSTALLING A

It is recommended that acleanup. The auxiliary filmaximum filter pressure at 180 F (82 C). The ma30 psi (206 kPa) at 15 gpthrottle stall.

Install the auxiliary

512. CONNECTING

NOTE: An electronelectronic sassembly ismechanicalPARKING BRAKE CONTROL

rly adjust the parking brake linkage.oe-to-drum clearance as specified by the manufacturer.

COOLER, FILTER

cooler and filter line locations.

draulic lines are of the proper size and type recommended. als where required.be bracket(s) as required.ulic lines to the transmission and to the cooler and external ee that the lines are clean and unobstructed.tings at the transmission to the torque values shown on

nds, kinks, twists and for contact with components that will he oil lines.at the hydraulic lines are not in close proximity to st pipes. Excessive heat will hasten the deterioration of

UXILIARY FILTER

n auxiliary filter be installed in the cooler-circuit following ter must have a 40 micron (max) filter element and a drop of 2 psi (13 kPa) at 15 gpm (57 liters/minute)ximum cooler circuit pressure drop must not exceedm (57 liters/minute) at operating temperature and full

filter.

SPEEDOMETER DRIVE

ic speed signal is provided by the ECU to operate an peedometer. The mechanical speedometer driven gear required only if the vehicle is equipped with a speedometer.30

Figure 51. To

TRANSM

TRANSM

TRANS

AUXILIARFILTERrque Values of Typical Filter and Cooler Lines

TIGHTEN FITTINGSTO 4050 LB FT

(5468 Nm)

TIGHTEN FITTINGSTO 4050 LB FT

(5468 Nm)

FROM COOLER

AUXILIARY FILTER(RECOMMENDEDAFTER DEBRIS-CAUSING FAILURE)

TO FILTER

TO FILTER

TOFILTER

VIEW CISSIONS WITH OUTPUT RETARDER

VIEW BISSIONS WITH INPUT RETARDER

VIEW AMISSIONS WITHOUT RETARDER

TIGHTEN FITTINGSTO 4050 LB FT

(5468 Nm)

FROMFILTER

FROMFILTER

FROMFILTER

YTOCOOLER

FROMCOOLER

TO COOLER

TO COOLER

FROM COOLER

L0254331

Install the speedometer driven gear assembly into the transmission (if required). Tighten the gear assembly in the transmission rear cover to 4550 lb ft (6267is installed to closeassembly).

Install the speedomnut to 52 lb inch (6Bends must have a90 bend is allowe

513. INSTALLING TCONNECTING

Connect the electroconnector and to thturned until a posit

Install temperatureequipped, into the If equipped w

adapter suffici Install the bulb Check the cap

or damage the If equipped w

connect electr Install and connect

equipment, and pre Install the pressure If a reverse pressur

pressure port, mak Check that all unu

514. FILLING THE H

Select the transmis Fill the transmissio

Section 19). Run the engine for

(refer to Section 1 Nm). If no speedometer drive is provided, be sure the plug the hole in the housing (torque is same as for gear

eter drive cable onto the driven gear assembly. Tighten the Nm). Avoid kinks or sharp bends in the cable assembly. minimum radius of 6 inches (150 mm). No more than one d.

EMPERATURE AND PRESSURE SENSORS, ELECTRICAL COMPONENTS

nic control chassis harness to the transmission main e speed sensor connector. Be sure the main connector is ive snap is felt. probe (capillary tube and bulb, or thermocouple), if so converter housing or hydraulic retarder valve.ith capillary tube and bulb, tighten the 12 inch pipe thread ently to prevent leakage. into the adapter and tighten the nut into the adapter.

illary tube for interference with other parts that might chafe tube. Long tubes may require clips or brackets for support.ith electrical temperature sensor, install thermocouple and ical leads. other electrical components such as heaters, winterization ssure sensors. gauge tube, or line, if so equipped.e switch is mounted on the transmission at the reverse e the appropriate connection.sed hydraulic openings are plugged.

YDRAULIC SYSTEM

sion fluid.n with the required amount of fluid (refer to

about one minute and check the transmission fluid level 3).32

61. INSTALLATION

Use this list them off this

Torque Values Flexplate bolts Transmission- Transmission- Input flange nu Output flange Companion fla Speedometer c Speedometer b Hydraulic line Cooler lines to Drain plug Speed sensor b PTO mounting Reverse signal 4860 lb in. (5 Parking brake Center bolt ex

Cooler Fluid Line No Leaks Connection Ti Correct Routin

CHECKS AND SECTION

* Tighten to vehicle manufactu CHECKLIST

after transmission installation. As items are checked, mark list.

96115 lb ft (131155 Nm)to-engine bolts*to-frame or mounting bolts*t 450550 lb ft (611745 Nm)

nut 600800 lb ft (8141084 Nm)nge or universal joint bolts*able nut 52 lb in. (6 Nm)ody 4550 lb ft (6267 Nm)s-to-transmission 4050 lb ft (5567 Nm) max and from retarder 5059 lb ft (6879 Nm)1520 lb ft (2027 Nm)olt 2023 lb ft (2831 Nm) bolts* (if PTO used) switch to transmission, if so equipped.56.7 Nm)bolts to transmission 117140 lb ft (159189 Nm)ternal filter 75 lb in. (8.5 Nm)s and Air Hose

ADJUSTMENTS VI33

ghtnessg

rers recommendation

Throttle Position Proper Adjustm Correct routin

Parking Brake Proper clearan Adjustment fo Check for full

Input Retarder Adjustment fo Ease of operat

Driveline Proper indexin Proper drive sh Driveline back Lubricated uni

Hydraulic System Recommended Proper fluid le Proper calibra Properly vente Proper filler tu Clean and free Transmission fl

Instruments and Proper wiring Instruments, g Shift selector d Fluid temperat

Power Takeoff Proper control Correctly coup Properly connSensorent

g of cable and harness

cer full applicationrelease

r full open, closedion

g of universal and slip-jointsaft angleslashversals and slip-joints

fluidvel in transmissiontion of the dipstickd filler tubebe and oil pan connection of obstruction breatheruid leak

Electrical Equipmentand electrical connectionsauges, and light work correctlyisplay is on and DO NOT SHIFT light is offure gauge is working correctly

connection and operationled to driven equipment

ected and routed lubrication line if used34

62. ROAD TEST AND VEHICLE OPERATION CHECKLIST

a. Driveability. Drive-awsupport equipment instalaway check procedures:

Check Flu Start the V

Turn The DO NOT Start the engin The DO NOT

Clear Trouble Codbe stored in the eleto road testing the

Road Test the Vehishifts.

Check for Proper Ooperation, and chehoses.

Re-check for Trou(DDR) to determinLink or DDR to t

Troubleshoot ifcorrected. Refer toTS2712EN.

b. Service and MaintenElectronic Control Servicnance instructions. ReferControl Troubleshootingshooting. Refer to Sectio

NOTE: Refer to HT/CT Transmission Operators Handbook for operating instructionsay checks are performed to verify proper transmission and lation and operation. The following steps outline drive-

id fill the transmission with the appropriate fluid. ehicle check for proper system response during start-up.on the vehicle master/ignition switch.SHIFT light should come on.e.SHIFT light should go off.es during installation, it is common for false codes to ctronic controls ECU. These codes must be cleared prior vehicle. cle allow the electronic control time to converge

peration check all components for proper mounting and ck for transmission fluid leaks at gasket surfaces, lines, and

ble Codes use the Pro-Link or Diagnostic Data Reader e if codes were set during the road test. Connect the Pro-he ECU through the Diagnostic Data Link (DDL). codes exist after the road test, problems must be found and the latest edition of HT/CT Troubleshooting Manual

ance. Refer to the latest edition of the HT 700 Seriese Manual for detailed transmission service and mainte-

to the latest edition of the HT 700 Series Electronic Manual for detailed electronic control system trouble-n 72 for the latest publication number.

.35

c. Road Test Checklist. Neutral Start Cir Starts only in n

Instruments DO NOT SHIF Transmission fl Speedometer Temperature g Reverse warni

Transmission Flu Fluid level me No leaks Warm-up and

No-Load Governe No-load gover Adjust governo

for the engine- PTO PTO operation

vehicle manuf Shift Sequence Transmission u

Other Checks Stall test Shift quality

Comments____________

____________

____________

____________

____________ Complete the following checklist.cuiteutral

T light and CHECK TRANS lightuid pressure gauge if used

auge if usedng system if usedidet specifications cold, neutral, level

check fluid level hot, neutral, leveld Engine Speedned speed of enginer as necessary refer to the manufacturers specifications transmission being tested.

refer to HT 700 Series Operators Manual or to the acturers specific instructions.

pshifts and downshifts smoothly through all ranges

_____________________________________________

_____________________________________________

_____________________________________________

_____________________________________________

_____________________________________________36

71. OWNER ASSIS

The satisfaction and goodconcern to Allison Trans

As an owner of an Allisoworld that are eager to m

Expert service by t Emergency service Complete parts sup Sales teams to help Product informatio

Normally, any situation tof your transmission willthe telephone directory f

Reference the Sales and Allison Transmission aut

We recognize, however, tmisunderstandings may odeveloped the following has not been handled sati

Step One Discuss thethe distributorship or dbreakdown in communicmanagement. If you haveManager, contact the Gendistributor. If the problemmanagement member of agreement. The dealer wtelephone number on reqTANCE

will of the owners of Allison transmissions are of primary mission Division (ATD), its distributors, and their dealers.n transmission, you have service locations throughout the eet your parts and service needs with:

rained personnel 24 hours a day in many areasport determine your transmission requirementsn and literature

hat arises in connection with the sale, operation, or service be handled by the distributor or dealer in your area (check or the Allison Transmission service outlet nearest you).Service Directory (SA2229EN) for the current listing of horized distributor and service dealers.

hat despite the best intentions of everyone concerned, ccur. To further assure your complete satisfaction, we have

three-step procedure to be followed in the event a problem sfactorily.

problem with a member of management from ealership. Frequently, complaints are the result of a

CUSTOMER SERVICE

SECTION VII37

ation and can quickly be resolved by a member of already discussed the problem with the Sales or Service eral Manager. All ATD dealers are associated with an ATD originates with a dealer, explain the matter to a

the distributorship with whom the dealer has his service ill provide his ATD distributors name, address, and uest.

Step Two When it appears the problem cannot be resolved readily at the distributor level without additional assistance, contact the Allison Transmission Regional Office responsible for the local distributor. You will be assisted by a member of the Regional Service Managers staff, depending on the nature of your problem.

For prompt assistance, pl

Name and location Type and make of Transmission mod

equipped with elec Transmission deliv Nature of problem Chronological sum

Step Three If you conpresent the entire matteor calling the phone nu

Manager, Warranty AdmAllison TransmissionP.O. Box 894Indianapolis, Indiana 462Phone: (317) 2423538The inclusion of all pertithe matter. If an additionindicates that some furth

When contacting the Regthe problem will likely bfacilities, equipment, andfollowed in sequence wh

Your purchase of an Allisour sincere desire to assuease have the following information available.

of authorized distributor or dealerequipmentel number, serial number, and assembly number (if tronic controls, also provide the ECU assembly number)ery date and accumulated miles and/or hours of operation

mary of units history

tacted a regional office and you are still not satisfied, r to the Home Office by writing to the following address mber below:

inistration PF9

060894

nent information will assist the Home Office in expediting al review by the Home Office of all the facts involved er action can be taken, the Regional Office will be advised.

ional or Home Office, please keep in mind that ultimately e resolved at the distributorship or dealership utilizing their personnel. Therefore, it is suggested the above steps be en experiencing a problem.

on Transmission product is greatly appreciated, and it is re complete satisfaction.38

72. SERVICE LITERATURE

Additional service literature is available. This service literature provides fully illustrated instructions for the operation, maintenance, service, overhaul, and parts support of your transmission. To ensure that you get maximum performance and service life from your unit, see your dealer or

distributor for the following publications. Check the telephone directory for the Allison Transmission service outlet nearest you.

Table 71. Service Literature

* Electronic Control Ser ** Automatic Transmissi

*** HT/CLBT Series Inspe**** HTB Series Hydraulic

Publication HTB 700 Series CLT, CLBT 700 SeriesService Manual SM2004EN

SM1992EN*SM1314ENSM1992EN*

Parts Catalog PC1965EN PC1993ENTroubleshooting Manual TS2712EN TS2712ENOperators Manual OM1957EN OM1957ENTechnicians Guide GN2009EN****

GN2033EN***GN2055EN**GN2033EN***vice Manual Supplementon Fluid ction/Analysis

Output Retarder Inspection/Analysis

GN2055EN**39

PC1958EN 199503 Printed in U.S.A. 199904

MT1958ENTITLE PAGEWARNINGS, CAUTIONS, AND NOTESTABLE OF CONTENTSPREFACE & TRADEMARKS USEDREPRESENTATIVE VIEWSModel HT 741, 748 Transmission Left-Rear ViewModel HT 741, 748 Transmission Right-Front ViewModel HT 755CR Transmission Left-Rear ViewModel HT 755CR Transmission Right-Front ViewModel HT 755DR Transmission Left-Rear View (With Input Retarder)Model HT 755DR Transmission Right-Front View (With Input Retarder)Model HTB 748 Transmission Left-Front View (With Output Retarder)Model HTB 748 Transmission Right-Rear View (With Output Retarder)Model CLBT 755 Transmission Left-Front ViewModel CLBT 755 Transmission Right-Front ViewPREVENTIVE MAINTENANCE11. PERIODIC INSPECTION AND CARE12. IMPORTANCE OF PROPER TRANSMISSION FLUID LEVEL13. TRANSMISSION FLUID CHECK PROCEDURESTable 11. Transmission Fluid CapacityCOLD CHECKHOT CHECKFigure 11. Typical Dipstick Markings

14. KEEPING TRANSMISSION FLUID CLEAN15. AUTOMATIC TRANSMISSION FLUID RECOMMENDATIONSTable 12. Operating Temperature Requirements for Transmission Fluid

16. TRANSMISSION FLUID AND FILTER CHANGE INTERVALSTable 13. Transmission Fluid and Filter Change IntervalsTable 14. Fluid Oxidation Measurement Limits

17. FLUID TEMPERATURESTable 15. Fluid Temperatures

18. HIGH-EFFICIENCY, MAIN PRESSURE EXTERNAL FILTER CHANGE19. TRANSMISSION FLUID CONTAMINATION110. TRANSMISSION FLUID AND FILTER CHANGE PROCEDURE111. Auxiliary FilterTable 16. Auxiliary Filter Recommendations

112. BREATHER113. TRANSMISSION STALL TEST AND NEUTRAL COOL-DOWN CHECK

REMOVING TRANSMISSION FROM VEHICLE21. DRAINING TRANSMISSION22. DISCONNECTING CONTROLSFigure 21. Disconnect Locations

23. UNCOUPLING FROM DRIVELINE, ENGINE, ANd VEHICLE24. REMOVING THE TRANSMISSION25. REMOVING INPUT AND OUTPUT FLANGES OR YOKES26. REBUILD, OVERHAUL INSTRUCTIONS

PREPARING TRANSMISSION FOR INSTALLATION31. CHECKING INPUT COMPONENTS32. INSTALLING OUTPUT FLANGE AND INPUT FLANGE (Remote-Mounted Transmission)33. INSTALLING PTO34. INSTALLING TRANSMISSION FILL TUBE AND SEAL35. CHECKING PLUGS, OPENINGS

PREPARING VEHICLE FOR TRANSMISSION INSTALLATION41. ENGINE, TRANSMISSION ADAPTATION REQUIREMENTS42. CHECKING FLEXPLATE DRIVE ASSEMBLY43. CHECKING INPUT DRIVE COMPONENTS (REMOTE-MOUNTED TRANSMISSIONS)Figure 41. Typical Method Of Coupling Transmission To EngineFigure 42. Converter Axial Location MeasurementFigure 43. Arrangement of Adaptation Components

44. CHASSIS AND DRIVELINE INSPECTION45. COOLER, FILTER, AND LINES46. CHECKING CONTROLSFigure 44. Throttle Position Determination DiagramFigure 45. Hitch-Pin Throttle Sensor Installation DiagramFigure 46. Slip-Link Throttle Sensor Installation Diagram

INSTALLING TRANSMISSION INTO VEHICLE51. HANDLING52. MOUNTING TO ENGINE53. INSTALLING TRANSMISSION MOUNTING COMPONENTS54. COUPLING TO DRIVELINE55. COUPLING TO ENGINE (REMOTE-MOUNTED TRANSMISSION)56. CONNECTING INPUT RETARDER CONTROL57. CONNECTING OUTPUT RETARDER CONTROL58. CONNECTING POWER TAKEOFF CONTROLS59. CONNECTING PARKING BRAKE CONTROL510. CONNECTING COOLER, FILTER511. INSTALLING AUXILIARY FILTER512. CONNECTING SPEEDOMETER DRIVEFigure 51. Torque Values of Typical Filter and Cooler Lines

513. INSTALLING TEMPERATURE AND PRESSURE SENSORS, CONNECTING ELECTRICAL COMPONENTS514. FILLING THE HYDRAULIC SYSTEM

CHECKS AND ADJUSTMENTS61. INSTALLATION CHECKLIST62. ROAD TEST AND VEHICLE OPERATION CHECKLIST

CUSTOMER SERVICE71. OWNER ASSISTANCE72. SERVICE LITERATURETable 71. Service Literature