Models FD, FE, FF and SG (ALLISON 2400, 2000 and … Service Manual...Models FD, FE, FF and SG (ALLISON 2400, 2000 and MD3060P) AUTOMATIC TRANSMISSION 75-1 1 page 1 75 TROUBLESHOOTING.....75-

Models FD, FE, FF and SG (ALLISON 2400, 2000 and MD3060P) AUTOMATIC TRANSMISSION 75-1

1 page 1

75

TROUBLESHOOTING...............................................................75 - 2

SPECIAL TOOL .........................................................................75 - 3

REMOVAL AND INSTALLATION OF TRANSMISSIONFor Models FD, FE and FF .......................................................75 - 4

(Allison 2400 and 2000)

REMOVAL AND INSTALLATION OF TRANSMISSIONFor Model SG ............................................................................75 - 11

(Allison MD3060P)

SHIFT CONTROL LINKAGE .....................................................75 - 18

ADJUSTMENT AND INSPECTION ...........................................75 - 24

75-01E-13

CHAPTER 75AUTOMATICTRANSMISSIONModels: FD and FE with Allison 2400

FF with Allison 2000SG with Allison MD3060P

1 INDEX

Models FD, FE, FF and SG (ALLISON 2400, 2000 and MD3060P)75-2 AUTOMATIC TRANSMISSION

1 page 1

TROUBLESHOOTING

NOTE: When diagnosing transmission problem, referto the Allison Shop Manual or troubleshootingprocedures for detailed information on itemsthat could be causing the problem.

Models FD, FE, FF and SG (ALLISON 2400, 2000 and MD3060P) AUTOMATIC TRANSMISSION 75-3

1 page 1

SPECIAL TOOL

Prior to removal and installing of automatic transmission, it is necessary to have this special tool.

Illustration Tool No. Tool name

09657-1370 SPACER COUPLING GUIDE

Models FD, FE and FF (ALLISON 2400 and 2000)75-4 AUTOMATIC TRANSMISSION

1 page 1

Fig. 3

SPEED SENSORHARNESS

PARKING BRAKE CABLE

PROPELLERSHAFT

1. BLOCK THE WHEELS.1. Park the vehicle on level ground.2. Block the wheels.NOTE: Be sure to apply wheel stoppers in the front

tires.

REMOVAL OF TRANSMISSIONFor Models FD, FE and FF (Allison 2400 and 2000)

NOTE: Allison transmission repairs are to be per-formed by an authorized Allison service dealer.

WARNINGDo not work on the transmission while it is still hot.This can result in personal injury.

3. REMOVE THE PROPELLER SHAFTS.1. Disconnect the yoke from the transmission flange,

and remove the center bearing holder.2. Move the forward end of the propeller shaft out of

the way.4. DISCONNECT THE PARKING BRAKE CABLE FROM

THE PARKING BRAKE LEVER AND BRACKET.5. REMOVE THE SPEEDSENSOR HARNESS FROM THE

REAR OF THE TRANSMISSION.

2. DRAIN THE TRANSMISSION FLUID.1. Place the drain pan under the transmission.2. Remove the drain plug from the transmission and

allow the fluid to drain.

SMAT-040

Fig. 1

SMAT-043

Fig. 2

Models FD, FE and FF (ALLISON 2400 and 2000) AUTOMATIC TRANSMISSION 75-5

1 page 1

6. DISCONNECT THE OIL COOLER LINES AT THETRANSMISSION.

ASM7-009

OIL FLOW

OIL FLOW

OIL COOLERLINES

Fig. 4

SMAT-102

Fig. 5

ASM7-010 ASM7-011Fig. 6

SMAT-048

Fig. 7

9. REMOVE INSPECTION COVER FROM THE BOTTOMFRONT SIDE OF THE FLYWHEEL HOUSING.

8. DISCONNECT THE NSBU SWITCH AND MAIN ELEC-TRICAL CONNECTOR.

7. DISCONNECT THE SHIFT CABLE FROM THE MANUALLEVER AT THE TRANSMISSION.

NSBUSWITCH

MAIN ELECTRICALCONNECTOR

Fig. 8

SMAT-049

10. REMOVE THE SIX COUPLING FROM THE FLYWHEELATTACHING BOLTS.1. Turn the flywheel manually to match the attaching

bolt to the slot on the inspection opening at the bot-tom front side of the flywheel housing.

2. Remove the coupling bolts one by one.


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SMAT-051

Fig. 9

Fig. 10

SMAT-050

11. REMOVE THE LOWER CONVERTER HOUSING FROMTHE FLYWHEEL HOUSING ATTACHING BOLTS.

12. POSITION A TRANSMISSION JACK UNDER THETRANSMISSION AND SECURE THE TRANSMISSIONTO THE JACK WITH A SAFETY CHAIN OR WIRECABLE.

13. REMOVE THE REMAINING CONVERTER HOUSINGFROM THE FLYWHEEL HOUSING ATTACHING BOLTS.

14. PULL OUT THE TRANSMISSION BACKWARDS.

WARNINGDo not lower the front end of the transmission. Iflowered, the torque converter may slide out of thetransmission and you may be injured.


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INSTALLATION OF TRANSMISSIONFOR MODEL FD, FE AND FF (ALLISON 2400AND 2000)1. TIGHTEN THE FLEX PLATE, SPACER COUPLING AND

WEAR PLATE.Tightening Torque: 800 - 900 kg·cm (58 - 65 lb·ft)NOTE: Before tightening, face the chamfered outer

rim of the wear plate to the flex plate. If as-sembled to the contrary, the wear plate edgehits the flex plate and its strength is reduced.

Fig. 3

2. TIGHTEN THE TORQUE CONVERTER AND THE FLEXPLATE.Tightening Torque: 520 - 622 kg·cm (38 - 44 lb·ft)NOTE: Apply grease containing molybdenum disul-

fide to the boss at the end of the torque con-verter before assembling. Without grease,the flex plate will not slide well and abnor-mal force will be generated, causing the flexplate to break.

Fig. 1

SMAT-052

Fig. 2

SMAT-053

Fig. 4

SMAT-054

FLEX PLATE

APPLYGREASE

TORQUECONVERTER

3. MOUNT THE TRANSMISSION ASSEMBLY ON ATRANSMISSION JACK. THEN MOVE THE ASSEMBLYINTO THE POSITION.



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Fig. 7

Fig. 8

Fig. 9

Fig. 6

Fig. 5

SMAT-056

SMAT-057

SMAT-058

SMAT-055

SM35-038

6. MOVE THE TRANSMISSION JACK SLOWLY AND IN-SERT THE GUIDE INTO THE FITTING HOLE OF THEFLYWHEEL SPACER COUPLING.NOTE: Do not lower the front side of the transmis-

sion. If lowered, the torque converter mayslide out of the transmission and you may beinjured.

9. LOWER AND REMOVE THE TRANSMISSION JACK.10. TAKE THE GUIDE OUT OF THE INSPECTION HOLE

ON THE FLYWHEEL HOUSING FRONT WITH A SCREWDRIVER.

7. MOVE THE TRANSMISSION JACK SLOWLY AND AD-JUST BY BRINGING THE FITTING FACES OF THETORQUE CONVERTER HOUSING AND THE FLY-WHEEL HOUSING TOGETHER.

8. TIGHTEN THE BOLTS TO JOIN THE TORQUE CON-VERTER HOUSING AND THE FLYWHEEL HOUSING.Tightening Torque: 522 - 622 kg·cm (38 - 44 lb·ft)

5. ROTATE THE ENGINE TO ALIGN THE FITTING HOLEOF THE ENGINE FLYWHEEL AND SPACER COUPLINGWITH THE INSPECTION HOLE ON THE FRONT OF THEFLYWHEEL HOUSING.

NOTE: First switch off power so that the engine will notstart.

4. SCREW THE SPECIAL TOOL "GUIDE" BY HAND INTOTHE SPACER COUPLING OF THE TRANSMISSIONASSEMBLY. ROTATE THE TORQUE CONVERTER SOTHAT THE GUIDE FACES DOWNWARD.Special Tool: Spacer coupling guide (09657-1370)


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SMAT-055

Fig. 10

Fig. 11

SMAT-059

Fig. 12

14. ATTACH THE TRANSMISSION SHIFT LEVER TO THETRANSMISSION CASE AND THE SHIFT CABLE TOTHE LEVER AND BRACKET.Tightening Torque: 207 - 276 kg·cm (15 - 19 lb·ft)NOTE: ● Do not drive the lever onto shaft by ham-

mering or bumping.● Move the lever to a detent position other

than reverse or 1st range and hold thelever by hand or adjustable wrench.

13. CONNECT THE NSBU SWITCH AND MAIN ELECTRI-CAL CONNECTOR.

11. LIGHTLY TIGHTEN THE BOLTS JOINING THE FLY-WHEEL AND THE SPACER COUPLING THROUGH THEINSPECTION HOLE. IN ORDER TO TIGHTEN THEBOLTS, TURN THE RING GEAR WITH A SCREWDRIVER THROUGH THE TIMING ADJUSTMENT HOLEON THE UPPER PART OF THE FLYWHEEL HOUSING.NOTE: If the ring gear does not turn smoothly with

a screw driver, remove the transmission andrepeat the procedure again from 6 above,because the hub ends of the flywheel and thespacer coupling do not fit well. Tighteningbolts in such a condition will cause damageto bolts and jamming of the engine.

12. TIGHTEN THE BOLTS PRETIGHTENED IN STEP 11.Tightening Torque: 650 - 870 kg·cm (47 - 62 lb·ft)

ASM7-010 ASM7-011

NSBUSWITCH

MAIN ELECTRICALCONNECTOR

Fig. 13

ASM7-009

OIL FLOW

OIL FLOW

OIL COOLERLINES

15. CONNECT THE OIL COOLER LINE.1. For connecting the transmission case and joints, in-

sert O-rings in the grooves of the joints before tight-ening.

NOTE: Apply ATF to the O-rings when insertingthem. If ATF is not applied, the O-rings willnot be inserted smoothly and will thus bedamaged, causing oil to leak.


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Fig. 14

Fig. 15

SPEEDSENSORHARNESS

PARKING BRAKECABLE

PROPELLERSHAFT

16. INSTALL THE SPEEDSENSOR HARNESS TO THEREAR PART OF THE TRANSMISSION.

17. ATTACH THE PARKING BRAKE CABLE TO THE PARK-ING BRAKE LEVER AND TO THE BRACKET.

18. INSTALL THE PROPELLER SHAFT YOKE TO THETRANSMISSION FLANGE.Tightening Torque:

FD, FE, FF: 650 - 870 kg·cm (47 - 62 lb·ft)19. INSTALL THE CENTER BEARING HOLDER TO THE

FRAME.

20. REMOVE THE CAP OF THE OIL FILLER TUBE ANDPOUR TRANSMISSION FLUID INTO THE TUBE.Fluid to be Used: ATF DEXRON IIIOil Volume: Refer to Item 4. CHECK THE TRANSMIS-

SION FLUID LEVEL on Page 75-26.NOTE: ● For further details, consult your nearest

ALLISON representative or ALLISON ser-vice station.

● Vehicles shipped from the HINO factorycontain DEXRON III type fluid.

Model SG (ALLISON MD3060P) AUTOMATIC TRANSMISSION 75-11

REMOVAL OF TRANSMISSIONFor Model SG (Allison MD3060P)

NOTE: Allison transmission repairs are to be per-formed by an authorized Allison servicedealer.

WARNINGDo not work on the transmission while it is still hot.This can result in personal injury.

1. BLOCK THE WHEELS.1. Park the vehicle on level ground.2. Block the wheels.NOTE: Be sure to apply wheel stoppers in the front

tires.

3. REMOVE THE PROPELLER SHAFTS.1. Disconnect the yoke from the transmission flange,

and remove the center bearing holder.2. Move the forward end of the propeller shaft out of

the way.

Fig. 1

SMAT-040

Fig. 3

SMAT-075

Fig. 2

SMAT-045

2. DRAIN THE TRANSMISSION FLUID.1. Place the drain pan under the transmission.2. Remove the drain plug from the transmission and

allow the fluid to drain.

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Model SG (ALLISON MD3060P)75-12 AUTOMATIC TRANSMISSION

Fig. 4

4. REMOVE THE SPEED SENSOR HARNESS FROM THEREAR OF THE TRANSMISSION.

5. DISCONNECT THE OIL COOLER LINES AT THETRANSMISSION.

6. DISCONNECT THE FEEDTHROUGH HARNESS CON-NECTOR.

SMAT-076

ASM7-013

ASM7-012

Fig. 6

Fig. 5

FROMCOOLER

TO COOLER

FEEDTHROUGHHARNESSCONNECTOR

Fig. 8

7. REMOVE INSPECTION COVER FROM THE BOTTOMFRONT SIDE OF THE FLYWHEEL HOUSING.

8. REMOVE THE SIX COUPLING FROM THE FLYWHEELATTACHING BOLTS.1. Turn the flywheel manually to match the attaching

bolt to the slot on the inspection opening at the bot-tom front side of the flywheel housing.

2. Remove the coupling bolts one by one.

SMAT-048

Fig. 7

SMAT-049

OIL FLOW

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SMAT-065

9. REMOVE THE CONVERTER HOUSING ATTACHINGBOLTS.

10. POSITION A TRANSMISSION JACK UNDER THETRANSMISSION AND SECURE THE TRANSMISSIONTO THE JACK WITH A SAFETY CHAIN OR WIRECABLE.

11. REMOVE THE REMAINING CONVERTER HOUSINGFROM THE FLYWHEEL HOUSING ATTACHING BOLTS.

12. PULL OUT THE TRANSMISSION BACKWARDS.


SM75-011

Fig. 10

Fig. 9

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FLEX PLATE

INSTALLATION OF TRANSMISSIONFor Model SG (Allison MD3060P)1. TIGHTEN THE FLEX PLATE, SPACER COUPLING AND

WEAR PLATE.Tightening Torque: 653 - 867 kg·cm (47 - 63 lb·ft)NOTE: Before tightening, face the chamfered outer

rim of the wear plate to the flex plate. If as-sembled to the contrary, the wear plate edgehits the flex plate and its strength is reduced.Painted surface of the wear plate should belocated facing the transmission side.

2. TIGHTEN THE TORQUE CONVERTER AND THEADAPTER PLATE.

Tightening Torque: 245 - 296 kg·cm (18 - 21 lb·ft)NOTE: Apply grease containing molybdenum disul-

fide to the boss at the end of the torque con-verter before assembling. Without grease,the flex plate will not slide well and abnor-mal force will be generated, causing the flexplate to break.

3. INSTALL THE ASSEMBLY CONSISTING OF FLEXPLATE, COUPLING PLATE AND WEAR PLATE TO THECONVERTER. THEN TIGHTEN THE FLEX PLATE ANDADAPTER PLATE TOGETHER.Tightening Torque: 449 - 551 kg·cm (32 - 40 lb·ft)

4. MOUNT THE TRANSMISSION ASSEMBLY ON ATRANSMISSION JACK. THEN MOVE THE ASSEMBLYINTO THE POSITION.


5. SCREW THE SPECIAL TOOL "GUIDE" BY HAND INTOTHE SPACER COUPLING OF THE TRANSMISSIONASSEMBLY. ROTATE THE TORQUE CONVERTER SOTHAT THE GUIDE FACES DOWNWARD.Special Tool: Spacer coupling guide (09657-1370)

SM5-038

Fig. 5

Fig. 4

SM75-011

Fig. 3

SMAT-078

Fig. 2

Fig. 1

SMAT-052

APPLYGREASE

TORQUECONVERTER

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6. ROTATE THE ENGINE TO ALIGN THE FITTING HOLEOF THE ENGINE FLYWHEEL AND SPACER COUPLINGWITH THE INSPECTION HOLE ON THE FRONT OF THEFLYWHEEL HOUSING.NOTE: First switch off the power so that the engine

will not start.7. MOVE THE TRANSMISSION JACK SLOWLY AND IN-

SERT THE GUIDE INTO THE FITTING HOLE OF THEFLYWHEEL.NOTE: Do not lower the front side of the transmis-

sion. If lowered, the torque converter mayslide out of the transmission and you may beinjured.

8. MOVE THE TRANSMISSION JACK SLOWLY AND AD-JUST BY BRINGING THE FITTING FACES OF THETORQUE CONVERTER HOUSING AND THE FLY-WHEEL HOUSING OR ADAPTER HOUSING TO-GETHER.

9. TIGHTEN THE BOLTS TO JOIN THE TORQUE CON-VERTER HOUSING AND THE FLYWHEEL HOUSING.Tightening Torque: 522 - 622 kg·cm (38 - 44 lb·ft)

10. LOWER AND REMOVE THE TRANSMISSION JACK.11. TAKE THE GUIDE OUT OF THE INSPECTION HOLE

ON THE FLYWHEEL HOUSING FRONT WITH A SCREWDRIVER.

FLYWHEEL

SPACERCOUPLING

GUIDE

BOLT

FLYWHEELHOUSING

ADAPTER

TORQUE CONVERTERHOUSING

Fig. 6

SM75-023

Fig. 7

SMAT-058

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Fig. 8

SMAT-055

Fig. 9

SMAT-076

12. LIGHTLY TIGHTEN THE BOLTS JOINING THE FLY-WHEEL AND THE SPACER COUPLING THROUGH THEINSPECTION HOLE. IN ORDER TO TIGHTEN THEBOLTS, TURN THE RING GEAR WITH A SCREWDRIVER THROUGH THE TIMING ADJUSTMENT HOLEON THE UPPER PART OF THE FLYWHEEL HOUSING.NOTE: If the ring gear does not turn smoothly with

a screw driver, remove the transmission andrepeat the procedure again from 6 above,because the hub ends of the flywheel and thespacer coupling do not fit well. Tighteningbolts in such a condition will cause damageto the bolts and jamming of the engine.

13. TIGHTEN THE BOLTS PRETIGHTENED IN STEP 11.Tightening Torque: 650 - 870 kg·cm (47 - 62 lb·ft)

14. INSTALL THE SPEEDSENSOR HARNESS TO THEREAR PART OF THE TRANSMISSION.

Fig. 11

15. CONNECT THE FEEDTHROUGH HARNESS CONNEC-TOR.

16. INSTALL THE PROPELLER SHAFT YOKE TO THETRANSMISSION FLANGE.Tightening Torque: 1,300 - 1,600 kg·cm (95 - 115 lb·ft)

17. INSTALL THE CENTER BEARING HOLDER TO THEFRAME.

ASM7-012

Fig. 10

SMAT-080

FEEDTHROUGHHARNESSCONNECTOR

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Fig. 12

ASM7-013

18. CONNECT THE OIL COOLER LINE.1. For connecting the transmission case and joints, in-

sert O-rings in the grooves of the joints before tight-ening.

NOTE: Apply ATF to the O-rings when insertingthem. If ATF is not applied, the O-rings willnot be inserted smoothly and will thus bedamaged, causing oil to leak.

19. REMOVE THE CAP OF THE OIL FILLER TUBE ANDPOUR TRANSMISSION FLUID INTO THE TUBE.Fluid to be Used: ATF DEXRON IIIOil Volume: Refer to Item 4. CHECK THE TRANSMIS-

SION FLUID LEVEL on Page 75-26.NOTE: ● For further details, consult your nearest

ALLISON representative or ALLISON ser-vice station.

● Vehicles shipped from the HINO factorycontain DEXRON III type fluid.

FROMCOOLER

TO COOLER

OIL FLOW

1 page 1


1 page 1

2

1

3

4

2

ASM7-019

1. REMOVAL OF THE SELECTOR LEVER ASSEMBLY.1. Remove the console box.2. Disconnect the pilot lamp harness.

SHIFT CONTROL LINKAGE

1. Selector lever assembly2. Lock nut3. Shift cable assembly4. Clanp

Fig. 1

Fig. 2


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3. Disconnect the shift cable from the selector leverassembly.

4. Remove the clamp and grommet from the floor ofthe cab.

5. Remove the selector lever assembly from the floorof the cab.

2. REMOVAL OF THE SHIFT CABLE1. Raise the cab (Refer to OWNER'S MANUAL, cab

tilt procedure).

WARNINGSecure the safety pin.After raising the cab, completely insert the safetypin in the safety pin hole.Otherwise the cab might come down and causepersonal injury.

Fig. 3

SMAT-099

Fig. 4

Fig. 5

SMAT-101

LOCKING COMPLETESafety pin holder is completely in contactwith the cab stopper stay, and the pinholder is turned in the down position.

SAFETY PIN

LOCKING INCOMPLETESafety pin is not completely inserted, or isnot turned in the down position.

SAFETY PIN

Fig. 6

SM19-500 SM19-500

SMAT-100


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2. Remove the pin and disconnect the manual lever atthe transmission. (Side of the transmission)

3. Disconnect the shift cable from the bracket.

ASM8-020

Fig. 7

ASM8-091-1

Fig. 8

Fig. 9

SMAT-104

Fig. 10

2. Replace the bush.a. Remove the old bushing.b. Install the new bushing.

INSPECTION AND REPAIRINSPECT THE SHIFT CABLE END.1. Check the shift cable for wear and damage.

If necessary, replace the parts.

4. Remove the cable.a. Remove the cable fitting bolts.b. Remove the cable fitting clamp.

SELECTOR LEVER

Fig. 11

3. Replace the pilot lamp bulb, if necessary.

SMAT-105


1 page 1

Fig. 14

1. INSTALL THE SELECTOR LEVER ASSEMBLY.1. Install the selector lever assembly to the floor of the

cab.

2. Install the shift cable fitting clamp and grommet.

3. Connect the shift cable to the selector lever.NOTE: When connecting the shift cable, it must be

connected to the selector lever at the centerhole of the selector lever.

Tightening Torque: 190 - 260 kg·cm (14 - 18 lb·ft)

SMAT-099

SMAT-100

Fig. 13

Fig. 12

SMAT-101

4. Install the console box.5. Connect the pilot lamp harness.


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RR

LOCKING COMPLETESafety pin holder is completely in contactwith the cab stopper stay, and the pinholder is turned in the down position.

SAFETY PIN

LOCKING INCOMPLETESafety pin is not completely inserted, or isnot turned in the down position.

SM19-500 SM19-500

Fig. 16

ASM8-019-02

2. Install the shift cable.a. Install the shift cable fitting bolts.b. Install the shift cable fitting clamp.

NOTE: The shift cable should not bent sharply. Anylooping should have a radius of more than150 mm (5.906 in.).

2. INSTALL THE SHIFT CABLE.1. Raise the cab (Refer to OWNER'S MANUAL, cab

tilt procedure).

WARNINGSecure the safety pin.After raising the cab, completely insert the safetypin in the safety pin hole.Otherwise the cab might come down and causepersonal injury.

Fig. 15

SAFETY PIN


1 page 1

ASM8-020SELECTOR LEVER

3. Connect the shift cable to the transmission lever toalign with hole in lever. Refer to section "ADJUST-MENT AND INSPECTION" for detailed adjusting.

4. Connect the shift cable at the support bracket andtighten the nuts temporarily.

Fig. 17


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1. Position the transmission selector lever in the "N"position.

ADJUSTMENT AND INSPECTION1. ADJUST THE SELECTOR LEVER LINKAGE.

Proper adjustment of the manual selector lever link-age is important because the shift lower gate posi-tions must correspond exactly to the detents in thetransmission. Periodic checks should be made forbent or worn parts, loose bolts or threaded connec-tions and accumulation of grease and dirt. All mov-ing joints should be kept clean and lubricated.The selector lever should move easily and give a feelof positive engagement in each position. The pinthat engages the selector lever linkage at the trans-mission should move freely in each range. Refer toAdjustment and Inspection in this section.

NOTE: This Manual shows in case of ALLISON 2000TYPE. (MODEL: FF)2400 TYPE is ADDED parking range to thiscase. (Models: FD, FE)

2. Disconnect the shift cable lock nut.

3. Shift the transmission manual lever to the "D" posi-tion.

ASM8-024

Fig. 3

Fig. 2

ASM8-023

SMAT-068A

Fig. 1

ADJUSTINGRANGE


1 page 1

4. With the transmission selector lever in the “D” posi-tion, adjust the shift cable by lock nut then connectthe shift cable to the manual lever and pin.

5. Tighten the lock nuts of the shift cable after adjust-ment.Adjustment for above procedure shall be carried outat “J”

6. Place the selector lever in all positions to make cer-tain that the manual lever at the transmission hasfull detent in all gear ranges. It may be necessary toreadjust the shift cable slightly to obtain detent in alldrive ranges.

Fig. 5

ASM8-022

ASM8-021

Fig. 4

SELECTORLEVER

SHIFT CABLEBRACKET

SELECTORLEVER

SHIFT CABLEBRACKET

Fig. 6

Fig. 7

SMAT-061

2. TRANSMISSION DRAINING AND REFILLING1. If the fluid is cold, operate the transmission until a

normal operating temperature, 71 - 93˚C (160 -200˚F), is reached.

2. Remove the drain plug from the transmission panand allow the fluid to drain.

3. When the fluid has stopped draining, replace thedrain plug.

4. Remove the dipstick and pour approximately tenquarts of transmission fluid into the transmissionthrough the filler tube.

SMAT-043


1 page 1

Fig. 10

5. With the vehicle standing level, apply the parkingbrake and place the selector lever in N. Operate theengine at idling speed.

6. If the transmission fluid is cold, operate the trans-mission until normal operating temperature isreached.

7. When the engine and transmission have reachedtheir normal operating temperatures, shift the selec-tor lever through all the range positions to make surethat warm fluid is distributed throughout the trans-mission. Return the selector lever to N.

8. Check the fluid level with the dipstick. The safe op-erating level is between the two HOT marks on thedipstick. If the fluid level is low, add sufficient fluidto bring the level between two HOT mark. If the levelis too high, drain excess fluid to attain a proper level.

3. CHECK THE TRANSMISSION FLUID LEVEL.With the truck standing level and the parking brakeapplied, start the engine and move the transmissionshift lever through all the shift positions, allowingsufficient time in each range to engage the transmis-sion. After engaging each transmission range, placethe selector lever in the N (NEUTRAL) position. Theengine should be running at idling speed and theengine and transmission at operating temperature.Do not turn off the engine during the fluid level check.

SMAT-073A

Fig. 8

SMAT-074

Fig. 9

SMAT-073A

Fig. 11

SMAT-074

1. Clean all dirt from the transmission fluid dipstick capbefore removing the dipstick from the filler tube.

2. Pull the dipstick out of the tube, wipe it clean, andpush it back into the tube. Be sure it is fully seated.

NOTE: The dipstick has two (2) hot marks and two(2) cold marks.

3. Hot oil checkEngine idling and transmission normal operatingtemperature 71 - 93˚C (160 - 200˚F) : pull the dip-stick out and check the fluid level. The level shouldbe between the two HOT marks. If additional fluidis required, add enough fluid through the filler tubeto bring the level between the two HOT marks onthe dipstick. Do not overfill the transmission, asfoaming and loss of fluid through the vent may re-sult in transmission malfunction.Fig. 12

SMAT-074


1 page 1

4. Cold oil checkEngine idling and transmission at 16 - 33˚C (60 -100˚F), cool to touch: pull the dipstick out and checkthe fluid level.The level should be between the bottom two COLDmarks. If additional fluid is required, add oil to bringthe level between the two COLD marks.

5. Replace the dipstick in the tube, making sure it isfully seated.Fig. 14

SMAT-074

Documents

Models FD, FE, FF and SG (ALLISON 2400, 2000 and … Service Manual...Models FD, FE, FF and SG (ALLISON 2400, 2000 and MD3060P) AUTOMATIC TRANSMISSION 75-1 1 page 1 75 TROUBLESHOOTING.....75-