Mechanic’s Tips

700 Series Hydraulic Controls

Allison On-Highway Transmissions
MT1366EN
MT1366EN intro.fm Page i Wednesday, January 5, 2005 3:53 PM

MT1366EN

Mechanic’s
Tips

Allison Transmission

700 Series
With Hydraulic Controls

April, 2004

Printed in U.S.A. i Copyright © 2004 General Motors Corp.

 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.

WARNING: A warning is used when an operating procedure, practice,

etc., if not correctly followed, could result in personal injury or loss of life.

CAUTION: A caution is used when an operating procedure,

practice, etc., if not strictly observed, could result in damage to or
destruction of equipment.

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

essential to highlight.

ii
 TABLE OF CONTENTS
Paragraph Description Page

SECTION I PREVENTIVE MAINTENANCE

1–1 Periodic Inspection and Care . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1–2 Importance of Proper Transmission Fluid Level . . . . . . . . . . . . 1
1–3 Aerated Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1–4 Fluid Level Check Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1–5 Keeping Transmission Fluid Clean . . . . . . . . . . . . . . . . . . . . . . 8
1–6 Automatic Transmission Fluid Recommendations . . . . . . . . . . 8
1–7 Fluid Temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1–8 Transmission Fluid and Filter Change Intervals . . . . . . . . . . . . 10
1–9 Transmission Fluid Contamination . . . . . . . . . . . . . . . . . . . . . . 12
1–10 Auxiliary Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1–11 Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1–12 Transmission Stall Test and Neutral Cool-Down Check . . . . . . 14

SECTION II REMOVING TRANSMISSION FROM VEHICLE

2–1 Draining Transmission Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2–2 Disconnecting Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2–3 Uncoupling From Driveline, Engine . . . . . . . . . . . . . . . . . . . . . 18
2–4 Removing Mounting Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2–5 Removing The Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2–6 Removing Input and Output Flanges or Yokes . . . . . . . . . . . . . 19
2–7 Rebuild, Overhaul Instructions . . . . . . . . . . . . . . . . . . . . . . . . . 20

SECTION III PREPARING TRANSMISSION

FOR INSTALLATION
3–1 Checking Flywheel (Engine-Mounted Models). . . . . . . . . . . . . 21
3–2 Installing Brake, Output Flange . . . . . . . . . . . . . . . . . . . . . . . . . 21
3–3 Installing Input Flange (Remote-Mounted Models) . . . . . . . . . 22
3–4 Installing Shift Selector Lever . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3–5 Installing PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3–6 Connecting Shift Modulator Control . . . . . . . . . . . . . . . . . . . . . 25
3–7 Installing Oil Fill Tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3–8 Front Mounting Spacers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

iii
Paragraph Description Page

SECTION IV PREPARING VEHICLE FOR TRANSMISSION

INSTALLATION
4–1 Engine, Transmission Adaptation Requirements. . . . . . . . . . . . 27
4–2 Checking Flexplate Assembly
(Engine-Mounted Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4–3 Checking Input Drive Components
(Remote-Mounted Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4–4 Checking Chassis, Driveline . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4–5 Cooler, Filter, and Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4–6 Checking Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

SECTION V INSTALLING TRANSMISSION INTO VEHICLE

5–1 Handling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5–2 Mounting to Engine (Engine-Mounted Models) . . . . . . . . . . . . 31
5–3 Installing Mounting Components. . . . . . . . . . . . . . . . . . . . . . . . 32
5–4 Coupling to Engine (Remote-Mounted Models) . . . . . . . . . . . . 32
5–5 Coupling to Driveline. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5–6 Connecting Cooler and Filter Lines . . . . . . . . . . . . . . . . . . . . . . 33
5–7 Connecting Shift Selector Control . . . . . . . . . . . . . . . . . . . . . . . 35
5–8 Connecting Hydraulic Input Retarder Control. . . . . . . . . . . . . . 37
5–9 Connecting Modulator Control . . . . . . . . . . . . . . . . . . . . . . . . . 37
5–10 Connecting Power Takeoff Controls . . . . . . . . . . . . . . . . . . . . . 40
5–11 Connecting Parking Brake Control . . . . . . . . . . . . . . . . . . . . . . 41
5–12 Connecting Output Disconnect Shaft Controls
(Dropbox Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5–13 Connecting Speedometer Drive . . . . . . . . . . . . . . . . . . . . . . . . . 41
5–14 Installing Temperature and Pressure Sensors,
Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5–15 Filling the Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

SECTION VI CHECKS AND ADJUSTMENTS

6–1 Road Test and Vehicle Operation Checklist . . . . . . . . . . . . . . . 43
6–2 Installation Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

SECTION VII CUSTOMER SERVICE

7–1 Owner Assistance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
7–2 Service Literature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

iv
 PREFACE
This handbook is a mechanic’s reference for removing, installing, and maintaining
the HT 700(DB) and C(LB)T 700(DB) Series Automatic Transmissions. The
features of the transmission and vehicle involved in removal and installation
procedures are discussed. The information presented will help the mechanic to
remove, install, and maintain the transmission in a manner that assures satisfactory
operation and long service life. Six overall photographs of the HT 700 Series,
CLBT 700 Series, and the CLBT 700 (DB) Series with transfer gear housing
(dropbox) are in the front of this book. Each photograph shows the external features
and check points discussed throughout this book. Use these photos as a reference.
For additional detailed information, refer to HT Service Manual SM1270EN or
CL(B)T 700 Series Service Manual SM1314EN, and CLT 750 Preventive
Maintenance — Oil Field Applications PM1772EN.

TRADEMARKS USED
DEXRON® is a registered trademark of General Motor Corporation.
Viton® is a registered trademark of E.I. DuPont Denemours, Incorporated.
TranSynd™ is a trademark of Castrol, Ltd.

v
 INPUT RETARDER BREATHER
VALVE BODY FRONT MOUNTING
TEMPERATURE TRUNNION
SENSOR PORT
REAR
COVER

TRANSMISSION
MAIN HOUSING

NAMEPLATE TO COOLER
FROM COOLER
REVERSE TAP
FILL TUBE PROVISION H02353

Model CLBT 754 (Remote Mount) Transmission—Right-Front View

TO COOLER
BREATHER TEMPERATURE
SENSOR PORT
TRANSMISSION
MAIN HOUSING

REVERSE
TAP

NAMEPLATE

PREHEAT
PROVISION STARTER
RING GEAR
FILL TUBE FLYWHEEL
PROVISION
CONVERTER HOUSING
FROM COOLER MOUNTING PAD H02356

Model HT 754CR Transmission—Right-Front View

vi
 BREATHER CONVERTER HOUSING
MOUNTING PAD
TRANSMISSION
MAIN HOUSING STARTER
RING GEAR
TEMPERATURE
SENSOR PORT

NAMEPLATE

FLYWHEEL
REVERSE
TAP TO COOLER
PREHEAT
PROVISION FROM COOLER
FILL TUBE INPUT RETARDER
PROVISION VALVE BODY H02357

Model HT 750DR Transmission—Right-Front View

(With Input Retarder and Engine-Driven PTO Provision)

TO COOLER TEMPERATURE
BREATHER SENSOR PORT
STARTER
TRANSMISSION RING GEAR
MAIN HOUSING

NAMEPLATE

REVERSE
TAP
FLYWHEEL
PREHEAT
PROVISION CONVERTER HOUSING
MOUNTING PAD
FILL TUBE
PROVISION FROM COOLER H2530

Model HT 740 Transmission—Right-Front View

vii
 TRANSMISSION
MAIN HOUSING
RETARDER HOUSING
FIRST CLUTCH
(ADAPTER) HOUSING ENGINE-DRIVEN TOP
POWER TAKEOFF PAD
TRANSFER GEAR
HOUSING (DROPBOX) FLYWHEEL
DROPBOX
ADAPTER
HOUSING

MANUAL
DISCONNECT
CLUTCH

CONVERTER STARTER
HOUSING RING GEAR
FILL TUBE
PROVISION H02361

Model CLBT 754DB (Direct Mount) Transmission—Right-Front View

ENGINE-DRIVEN UPPER MANUAL

SIDE POWER DISCONNECT CLUTCH
TAKEOFF PAD

SHIFTER
SHAFT

7 INCH
OIL PAN

TRANSFER GEAR HOUSING

(DROPBOX)

LOWER REAR OUTPUT SHAFT H02363

Model CLBT 754DB Transmission—Left-Rear View

viii
MT1366EN manual.fm Page 1 Friday, April 16, 2004 4:07 PM

PREVENTIVE S ECTION
MAINTENANCE I

1–1. PERIODIC INSPECTION AND CARE

Clean and inspect the exterior of the transmission at regular intervals. The severity
of service and operating conditions will determine the frequency of such
inspections. Inspect the transmission for loose bolts, fluid leaks, or damaged or
loose hydraulic lines. Fluid leaks require immediate attention.

Modulator cable linkage at the engine fuel lever and Shift selector linkage must be
kept:
• Clean
• Properly adjusted
• Lubricated.

1–2. IMPORTANCE OF PROPER TRANSMISSION FLUID LEVEL

The transmission fluid cools, lubricates, and transmits hydraulic power. It is
important that the proper fluid level be maintained at all times. If the fluid level is
too low, the converter and clutches will not receive an adequate supply of fluid. If
the level is too high, the fluid will aerate, the transmission will overheat, and fluid
may be expelled through the breather or dipstick tube.

1–3. AERATED FLUID

• Aeration changes the viscosity and color of the transmission fluid to a thin
milky liquid and adversely affects transmission performance. The primary
causes of aeration are improper fluid, not enough fluid in the sump, too much
fluid in the sump, or a defective or missing sealring on the intake pipe of the
internal filter. A low fluid level will not completely cover the internal filter.
Therefore, fluid and air are drawn into the system by the input pump and are
directed to the control circuits and converter causing cavitational noises.
• A high fluid level (too much fluid) will cause the clutches to be partially
immersed in the sump fluid. Rotation of the clutches churns the fluid causing
it to become aerated. The aerated fluid can also cause overheating.

1
MT1366EN manual.fm Page 2 Friday, April 16, 2004 4:07 PM

1–4. FLUID LEVEL CHECK PROCEDURE

WARNING: Take the following precautions so that unexpected,

possible sudden vehicle movement is avoided. Whenever it becomes
necessary to leave the vehicle, even momentarily, while the engine is
running, place the transmission shift selector in Neutral, set the parking
brake and/or emergency brakes and chock the wheels.

a. Refill After Rebuild Or Overhaul

• After overhaul or rebuild, the system, including all external plumbing and
components such as filters and heat exchanger, must be refilled. Dropbox
models have to be refilled in both the main transmission section and the
dropbox section.

NOTE: The transmission sump and dropbox have independent fluid

systems and may require different fluids. Refer to Section 1–6,
Automatic Transmission Fluid Recommendations, for the type of
fluid required in the transmission and dropbox.

• The initial running of the engine after overhaul will cause a rapid drawdown
of the transmission fluid level. Check the fluid level several times during the
first few minutes of operation and add fluid as needed to maintain the level
within the COLD RUN band.
• Make an accurate check after the level has stabilized and the fluid is hot—
160–200˚F (71–93˚C). Refer to Paragraph 1–4c for proper fluid checking
procedures.

b. Fluid Level and Dipstick

• Figures 1–1 through 1–3 illustrate the fluid levels relative to the 41⁄ 2, 6, 7, and
81⁄ 2 inch deep oil pans. These fluid levels are referenced from the top of the oil
pan or the pan to transmission housing splitline.
NOTE: The calibration procedure explained below is applicable to
the 7 and 81⁄ 2 inch deep oil pan. The same procedure is applicable to
the 41⁄ 2 and 6 inch deep oil pan except use the dimensions shown in
Figures 1–1 and 1–2, respectively.

CAUTION: The COLD RUN band level (Figures 1–1 through 1–4) is
an approximate dimension to be established by the OEM/Customer at
installation. An exact HOT RUN band dimension and fluid level should
be established prior to the COLD RUN dimension and fluid level. A
HOT RUN check is required for proper operating fluid level.

2
MT1366EN manual.fm Page 3 Friday, April 16, 2004 4:07 PM

1.00 in.
(25.4 mm)
1.50 in. TOP OF OIL PAN
(38.1 mm)
FILL TUBE HOLE
1.75 in.*
(44.5 mm)
2.00 in.*
(50.8 mm)

HOT RUN BAND

160–200°F (71–93°C)
COLD RUN BAND
60–120°F (15–49°C)

* Approximate dimension. OEM/customer to establish cold run band at installation. V02370

Figure 1–1. Fluid Levels (41⁄2 Inch Deep Pan)

TOP OF
OIL PAN 1.50 in.
(38.1 mm)

3.00 in.* 2.50 in.

3.75 in.* (76.2 mm) (63.5 mm)
(95.2 mm) 4.81 in.
(122.2 mm) HOT RUN BAND
160–200°F (71–93°C)

OIL PAN

COLD RUN BAND FILL TUBE HOLE

60–120°F (16–49°C)

* Approximate dimension. OEM/customer to establish cold run band at installation. V02371

Figure 1–2. Fluid Levels (6 Inch Deep Oil Pan)

• To calibrate the new dipstick, strike a mark on the side of the fluid fill tube
(that has been installed) to correspond with the top of transmission oil pan,
referenced in Figure 1–3. Position the new dipstick down along the outside of
the fill tube, holding the top even with the top of the fill tube (where it would
rest if installed into the tube). Follow the contour of the fill tube with the
dipstick down to the mark previously scribed on the side of the fill tube
representing the top of the oil pan—mark the dipstick. Now, measure down
3
MT1366EN manual.fm Page 4 Friday, April 16, 2004 4:07 PM

2.5 inches (64 mm) below the top of the pan and scribe a line across the
dipstick (dipstick may not be vertical). This will be the top line of the HOT
RUN band as illustrated in Figure 1–3. At a point 1.0 inch (25 mm) below this
scribed line, scribe another line across the dipstick; this represents the bottom
of the HOT RUN band and the top of the COLD RUN band. Measure down
1.25 inches (32 mm) and scribe the bottom line for the COLD RUN band.
• Instruction sheet No. 244 that is included with Fill Tube and Dipstick Kit
P/N 29506008 has additional information regarding the proper calibration of
the new dipstick. Also, Service Information Letter 32-TR-93 has dipstick
calibration information.
c. Fluid Level Checks
• Add transmission fluid to the transmission through the fill tube opening after
dipstick calibration is completed. Be sure to use proper transmission fluid and
fluid containers as discussed in Sections 1–5 and 1–6. Refer to Table 1–1 for
approximate transmission fluid capacity.
Table 1–1. Transmission Fluid Capacity
Application U.S. Quarts Liters
41⁄ 2 inch (114 mm) oil pan 34 32
6 inch (152 mm) oil pan 30 28.5
7 inch (178 mm) oil pan 30 28.5
81⁄ 2 inch (215 mm) oil pan 43 41
Dropbox 2.6 2.5
NOTE: Does not include external circuits.

CAUTION: Do not overfill the dropbox. Overfilling can cause

excessive fluid temperatures. If fluid level is above the FULL line,
drain fluid as required to bring it to the proper level.

• Clean around the end of the fill tube before removing the dipstick. Dirt or
foreign matter must not be permitted to enter the transmission because it can
cause valves to stick, cause undue wear of transmission parts, or clog
passages. Check the fluid level by the following procedures and record any
abnormal level on your maintenance records.
• Always check the fluid level at least twice. Consistency is important in
maintaining accuracy. If inconsistent readings persist, check the transmission
breather and the vent hole in the dipstick fill tube to be sure they are clean and
free of debris. The vent hole is located on the underside of the fill tube just
below the seal of the dipstick cap.

4
MT1366EN manual.fm Page 5 Friday, April 16, 2004 4:07 PM

Difference between FULL and ADD levels is 2 U.S. quarts (1.9 liters).
HOT RUN BAND
160–200°F (71–93°C)

3.50 in.
2.50 in.
(89.9 mm)
(63.5 mm)
FULL
4.75 in.*
TOP OF ADD (120.6 mm)
OIL PAN

COLD RUN BAND

FILL TUBE HOLE 60–120°F (16–49°C)
* Approximate dimension. OEM/customer to establish cold run band at installation.
V02372

Figure 1–3. Fluid Levels (7 and 81⁄2 Inch Deep Oil Pan)

CAUTION:
• The fluid level rises as sump temperature increases. DO NOT fill
above the COLD RUN band if the transmission fluid is below
normal operating temperature.
• An unexplained increase in the amount of sump fluid requires
immediate attention. A failed rear seal in the engine may be
allowing engine oil to enter the transmission sump (on wet
converter housing transmissions).

d. Cold Check

NOTE: The only purpose of the cold check is to determine if the

transmission has enough fluid to be safely operated until a hot check
can be made.

• Run the engine for at least one minute. Shift to D (Drive) and then to
R (Reverse) to clear the hydraulic circuits of air. The sump temperature
should be between 60–120°F (16–50°C).
• Park the vehicle on a level surface and shift to N (Neutral). Apply the parking
and/or emergency brakes and allow the engine to idle (500–800 rpm). Chock
the wheels of the vehicle.

5
MT1366EN manual.fm Page 6 Friday, April 16, 2004 4:07 PM

• After wiping the dipstick clean, check the fluid level. If the fluid on the
dipstick is within the COLD RUN band, the level is satisfactory for operating
the transmission until the fluid is hot enough to perform a HOT RUN check. If
the fluid level is not within the COLD RUN band, add or drain fluid as
necessary to bring the level to the middle of the COLD RUN band.
• Perform a hot check after normal operating sump temperature 160–200°F
(71–93°C) is reached.

TRANSMISSION-TO-OIL PAN SPLITLINE

(TOP OF OIL PAN)

1.00 1.50
1.50 (25.4) 2.50 (38.1)
1.75* (38.1) 3.00* (63.5)
(44.4) (76.2)
RU T

2.00*

RU T
3.75*
HO
N

HO
N
(50.8) (95.2)
RU LD

RU LD
N

N
CO

CO
WITH 41⁄ 2 INCH DEEP PAN
WITH 6 INCH DEEP PAN
E
IDL

DIMENSIONS ARE IN
T
LA

INCHES (MILLIMETERS)
2.50
RA

(63.5)
UT

3.50
NE

(88.9)
IN

4.75* PROCEDURE:
K

(120.6) USE HOT RUN BAND FOR 160–200°F (71–93°C)

EC

USE COLD RUN BAND FOR 60–120°F (16–49°C)

CH
RU T

NOTE:
HO
N

This illustration is not a template.

Placement of the markings will vary
according to the angle of the
RU LD
N

dipstick protruding into the fluid.

CO

Dimensions shown are in the

vertical plane.

*Approximate dimension. OEM/Customer

WITH 7 OR 81⁄ 2 INCH DEEP PAN to establish cold run band at installation. V02374

Figure 1–4. Dipstick Markings Location

6
MT1366EN manual.fm Page 7 Friday, April 16, 2004 4:07 PM

2 in.
(51 mm)
FULL
CLOUTPUT SHAFT
3 in.
(76 mm)
ADD

FLUID DRAIN PLUG

3 ⁄4-14 NPTF
FILL PIPE AND LEVEL INDICATOR V02375

Figure 1–5. Dropbox Fluid Levels (Front View)

e. Hot Check

NOTE: The fluid must be hot to ensure an accurate check. The fluid
level rises as temperature increases.

• Drive the vehicle until the transmission fluid reaches normal operating
temperature:
60–200°F (71–93°C) sump temperature
80–220°F (82–104°C) converter-out temperature
• Park the vehicle on a level surface and shift to N (Neutral). Apply the parking
and/or emergency brakes and allow the engine to idle (500–800 rpm). Chock
the wheels of the vehicle.
• After wiping the dipstick clean, check the fluid level. The safe operating level
is anywhere within the HOT RUN band on the dipstick. If the level is not
within this band, add or drain fluid as necessary to bring the level to the top of
the HOT RUN band. DO NOT OVERFILL.
f. Fluid Level Check In Dropbox
• The proper FULL and ADD fluid levels in the dropbox are shown in Figure 1–5.
These levels are on a vertical line through the bottom output shaft.
• The FULL and ADD marks on the dipstick should coincide with the fluid
levels shown in Figure 1–5.
• If fluid level is above the FULL line, drain fluid as required to bring it to the
proper level. If fluid is below the ADD line, add fluid as required to bring it to
the proper level.

7
MT1366EN manual.fm Page 8 Friday, April 16, 2004 4:07 PM

1–5. KEEPING TRANSMISSION FLUID CLEAN

CAUTION: Containers or fillers that have been used for any antifreeze
or engine coolant solution must never be used for the transmission fluid.
Antifreeze and coolant solutions contain ethylene glycol which, if
introduced into the transmission, can cause the clutch plates to fail.

Transmission fluid must be handled in clean containers, fillers, etc., to prevent

foreign material from entering the transmission. Clean around the filler tube before
removing the dipstick. Lay the dipstick in a clean place while filling the
transmission.

1–6. AUTOMATIC TRANSMISSION FLUID RECOMMENDATIONS

• Hydraulic fluids (oils) used in the transmission are important influences on
transmission performance, reliability and durability. TranSynd™ or another
TES-295 fluid is recommended for all on-highway and general applications.
DEXRON®-III can also be used in on-highway or general applications. Type
C-4 fluids are recommended for severe-duty and off-highway applications.
• Some DEXRON®-III fluids are also qualified as Type C-4 fluids. To be sure the
fluid is qualified for use in Allison transmissions, check for a DEXRON®-III or
C-4 fluid license, or approval numbers on the container, or consult the lubricant
manufacturer. Consult your Allison Transmission dealer or distributor before
using other fluid types; fluid types such as Type F, and universal farm fluids may
or may not be properly qualified for use in your Allison transmission.

CAUTION: Disregarding minimum fluid temperature limits can result

in transmission malfunction or reduced transmission life.

• When choosing the optimum viscosity grade of fluid to use, the following
must be taken into consideration:
— Duty cycle
— Preheat capabilities
— Geographical location.
• Table 1–2 lists the minimum fluid temperatures at which the transmission may
be safely operated. Preheat with auxiliary heating equipment or by running
the vehicle with the transmission in N (Neutral) for a minimum of 20 minutes
before attempting range operation.
• Use only type C-4, Grade SAE 30 transmission fluid in the dropbox.

8
MT1366EN manual.fm Page 9 Friday, April 16, 2004 4:07 PM

Table 1–2. Operating Temperature Requirements

for Transmission Fluid

Minimum Operating Temperature

SAE Viscosity Grade* Or Oil Type Degrees (C) Degrees (F)
0W-20 (Arctic Oil) or TranSynd™ –30 –22
DEXRON®-III –25 –13
10W –20 –4
15W-40 –15 5
SAE 30 0 32
SAE 40 10 50
* SAE “W” designation means winter weight based on cold temperature properties.

1–7. FLUID TEMPERATURES

• If the temperature sensor is located in the converter housing or input retarder
valve, the critical temperatures are listed in the converter-out column. If the
temperature sensor is located in some other area, refer to the vehicle manual
for the critical temperatures. If the maximum fluid temperature is reached,
follow this procedure:
— Stop the vehicle and shift the transmission into N (Neutral) and
operate the engine at 1500 rpm to reduce the transmission fluid
temperature.
— If the transmission fluid does not cool in approximately 30 seconds,
or if it continues to overheat after operation is continued, stop the
vehicle and engine and locate the problem.

Table 1–3. Fluid Temperatures

Converter-Out
Converter Operation — CLBT 700 Series 275˚F (135˚C) max
— HT 700 Series 300˚F (149˚C) max
Retarder Operation— Intermittent 330˚F (166˚C) max
Lockup Operation 250˚F (121˚C) max
Normal Operation 180–220˚F (82–105˚C)

9
MT1366EN manual.fm Page 10 Friday, April 16, 2004 4:07 PM

1–8. TRANSMISSION FLUID AND FILTER CHANGE INTERVALS

Filters to be changed include the following:
• Standard main-pressure external filter or high-efficiency main-pressure
external filter
• Governor filter
• Suction screen in the oil pan.

NOTE: The governor filter and suction screen in the oil pan should
only be changed at transmission overhaul.

a. Transmission Fluid Change

• Change transmission fluid every 50,000 miles (80 000 km) or 12 months or
1200 hours, whichever comes first. Fluid may require change sooner due to
adverse operating conditions. Fluid must be changed whenever there is
evidence of dirt or high temperature indicated by discoloration or change in
fluid analysis. Refer to Table 1–4 for applicable fluid analysis oxidation
measurement limits.

Table 1–4. Fluid Oxidation Measurement Limits

Measurement Limit
Viscosity +/-25% change from new fluid
Total acid number +3.0 change from new fluid
Solids 2% by volume maximum

• Transmission protection and fluid change intervals can be optimized by the

use of fluid analysis. However, filters must be changed at or before
recommended intervals.
• Consult your local industrial yellow pages for transmission fluid (oil) analysis
firms. Use only one analysis firm. Results between firms cannot be accurately
compared. Refer to Allison publication GN2055EN, Technician’s Guide for
Automatic Transmission Fluid, for additional information.

b. Standard Main-Pressure External Filter

• Change standard main-pressure external filter after the first 5000 miles
(8000 km) and thereafter as indicated in the following table.

10
 Schedule 1. Recommended Fluid and Filter Change Intervals (Non-TranSynd™/Non-TES 295 Fluid)

SEVERE VOCATION GENERAL VOCATION

Filters Filters
Fluid Fluid
Main Internal Lube/Auxiliary Main Internal Lube/Auxiliary
50,000 Miles 25,000 Miles Overhaul 25,000 Miles* 50,000 Miles 25,000 Miles Overhaul 25,000 Miles*
(80 000 km) (40 000 km) (40 000 km) (80 000 km) (40 000 km) (40 000 km)
12 Months 6 Months 6 Months 12 Months 6 Months 6 Months
1200 Hours 600 Hours 600 Hours 1200 Hours 600 Hours 600 Hours
NOTE:The following recommendations in Schedule 2 are based upon the transmission containing 100% of TranSynd™ fluid.
Flushing Machines are not recommended or recognized due to variation and inconsistencies with ensuring removal of 100% of the used
fluid.
Schedule 2. Recommended Fluid and Filter Change Intervals (TranSynd™/TES 295 Fluid)

11
50,000 Miles 25,000 Miles Overhaul 25,000 Miles* 100,000 Miles 50,000 Miles Overhaul 50,000 Miles*
MT1366EN manual.fm Page 11 Friday, April 16, 2004 4:07 PM

(80 000 km) (40 000 km) (40 000 km) (160 000 km) (80 000 km) (80 000 km)
24 Months 6 Months 6 Months 48 Months 12 Months 12 Months
1200 Hours 600 Hours 600 Hours 2400 Hours 1200 Hours 1200 Hours
* When an Allison recommended high-efficiency filter is used, the change interval is until the Change Filter light indicates the filter is contaminated or until it has
been in use for 3 years, whichever occurs first. No mileage restrictions apply. High-efficiency filters are only approved for use with AT/MT/HT Series.
NOTE: Change fluid/filters after recommended mileage, months, or hours have elapsed, whichever occurs first.
Severe Vocation: All Retarders, On/Off Highway, Refuse, Transit, and Intercity Coach with duty cycle greater than one (1) stop per mile.
General Vocation: Intercity Coach with duty cycle less than or equal to one (1) stop per mile and all other vocations.

Local conditions, severity of operation or duty cycle may require more or less frequent fluid change intervals that differ from the published
recommended fluid change intervals of Allison Transmission. Transmission protection and fluid change intervals can be optimized by the use of
fluid analysis. Filters must be changed at or before recommended intervals.
MT1366EN manual.fm Page 12 Friday, April 16, 2004 4:07 PM

c. Suction Filter and Governor Filter

• Change the suction and governor filters, located inside the transmission, only
at overhaul. Consult the appropriate service manual for detailed replacement
procedure.

d. Fluid and Filter Change Procedure

• The fluid should be warm when draining. This ensures quicker and better
drainage.
• On earlier models, remove the fill tube from the oil pan and allow the fluid to
drain. On later models, remove the drain plug from the rear of the oil pan and
allow the fluid to drain. Check the condition of the fluid as described in
Paragraph 1–9.
• On earlier models, install the filler tube at the side of the pan and tighten the
filter tube retainer nut to 90–100 lb ft (112–136 N·m). On later models, install
the oil drain plug at the rear of the oil pan and tighten the plug to 15–20 lb ft
(20–27 N·m).
• Remove the dipstick and pour approximately 30 quarts (28.4 liters) of
transmission fluid into the transmission through the filler tube. Then check the
fluid level using the procedure described in Paragraph 1–4.

1–9. TRANSMISSION FLUID CONTAMINATION

a. Examine At Fluid Change
At each transmission fluid change, examine the fluid that is drained for evidence of
dirt or water. A normal amount of condensation will emulsify in the fluid during
operation of the transmission. However, if there is evidence of water, check the
cooler (heat exchanger) for leakage between the water and fluid areas. Fluid in the
water side of the cooler (heat exchanger) is another sign of leakage. This, however,
may indicate leakage from the engine oil system.

b. Metal Particles

CAUTION: If excessive metal contamination has occurred, replace

the cooler and all bearings within the transmission.

Metal particles in the transmission fluid or on the magnetic drain plug (except for
the minute particles normally trapped in the filter) indicate damage has occurred in
the transmission. When these particles are found in the sump, the transmission must
be disassembled and closely inspected to find the source. Metal contamination will
require complete disassembly of the transmission and cleaning of all internal and

12
MT1366EN manual.fm Page 13 Friday, April 16, 2004 4:07 PM

external circuits, cooler, and all other areas where the particles could lodge. During
the repair of a major internal failure of a transmission, it should be dismantled into
as many serviceable detail parts as possible and thoroughly cleaned. Do not
disassemble the unit just to the problem area.

c. Coolant Leakage
• The presence of ethylene glycol coolant in the transmission fluid is
detrimental to the reliability and durability of the internal components.
Ethylene glycol has a deteriorating effect on friction-faced clutch plates and
nonmetallic components (seals, gasket, etc.) and on highly loaded steel parts,
such as bearings and gears, due to reduced lubricity of the fluid.
• If the presence of ethylene glycol in the fluid is suspected, immediately
perform a verification test. A Gly-Tek test kit is available and is a quick and
easy method to determine the presence of glycol. If glycol is found,
disassemble and inspect the transmission, and remove all traces of coolant and
varnish deposits resulting from coolant contamination. Replace all seals,
gaskets, and friction-faced clutch plates. Repair or replace the cooler prior to
installation of the new or rebuilt transmission.

1–10. AUXILIARY FILTER

• If a condition occurs that introduces debris into the transmission hydraulic
system, a complete cleanup of the cooler and lines is required.
• Because repeated cleaning and flushing may not remove all debris, install an
auxiliary filter in the cooler-out circuit (models without an output retarder), or
in the lubrication circuit (models with an output retarder). This
recommendation applies whether the transmission is overhauled or replaced
by a new or rebuilt unit.
• If any doubt exists about the cleanup of the cooler, replace the cooler.
• The auxiliary filter must have at least a 40-micron filter element or finer and a
maximum filter pressure drop of 3 psi (21 kPa) at 15 gpm (57 liters/minute) at
180˚F (82˚C). The maximum external circuit pressure drop must not exceed
30 psi (207 kPa) at 15 gpm (57 liters/minute) at operating temperature, in
D (Drive) at full throttle stall.

13
MT1366EN manual.fm Page 14 Friday, April 16, 2004 4:07 PM

• The following auxiliary filters are recommended:

Table 1–5. Auxiliary Filter Recommendations

Filter Assembly Filter Element

Allison 29510921* Allison 29510918*
AC PM 13-16 PF 897
AC PM 16-1 PF141
FX 11583 HF6520
Fram HP 1-1 HP 1 or AC HD 222
Purolator OF-15C-1 OF-2C-1
Purolator 20-10 PER-20
* High-efficiency filter and element are available from your authorized Allison distributor.
Ref: SIL 12-TR-93 (latest revision)

1–11. BREATHER
• The breather is located at the top of the transmission housing. It serves to
prevent pressure buildup within the transmission and must be kept clean and
the passage open. The prevalence of dust and dirt will determine the
frequency at which the breather requires cleaning. Use care when cleaning the
transmission. Spraying steam, water, and/or cleaning solution directly on the
breather can force water and cleaning solution into the transmission.
• Always use a wrench of the proper size to remove or replace the breather.
Pliers or a pipe wrench can crush or damage the stem and produce metal chips
which could enter the transmission.

1–12. TRANSMISSION STALL TEST AND

NEUTRAL COOL-DOWN CHECK
a. Purpose
The stall test provides a method for determining if the malfunction is in
the engine or in the transmission when the vehicle powerpack is not
performing satisfactorily.

• The neutral cool-down check utilizes the two-minute cooling period on the
stall test to gather fluid temperature data for troubleshooting reference.
• An extremely low stall speed, such as 33 percent of the specified engine stall
rpm, during which the engine does not smoke, could indicate a freewheeling
stator.

14
MT1366EN manual.fm Page 15 Friday, April 16, 2004 4:07 PM

• If the engine stall speed conforms to specification, but the transmission fluid
overheats, refer to the cool-down check. If the fluid does not cool during the
two-minute cool-down check, a stuck stator could be indicated.
• If the engine stall speed conforms to specification and the cool-down check
shows that transmission fluid cools properly, refer to the latest version of the
Troubleshooting Manual for further troubleshooting procedures.

b. Transmission Stall Test Procedure

• The actual engine stall point (rpm) under load is compared to the established
normal speed specified by the engine manufacturer.

NOTE: The engine data for the test is available from the engine
manufacturer or from your vehicle dealer or distributor.

• Connect a tachometer of known accuracy to the engine, and install a

temperature probe into the converter-out (to-cooler) line. Bring the
transmission to the normal operating converter-out temperature of 180–220°F
(82–104°C).

WARNING: When conducting a transmission stall test, the vehicle

must be prevented from moving. Apply the parking brake and service
brakes and block the vehicle securely. Warn personnel to keep clear of
the vehicle and its travel path. Failure to do so can cause serious injury.

CAUTION: Never maintain the stall condition for more than 30

seconds at any one time because of the rapid rise in fluid temperature.
Do not let the converter-out fluid temperature exceed 300°F (149°C).
Do not rely on converter-out fluid temperature to limit stall duration.
During stall conditions, internal temperatures rise much faster than
converter-out fluid temperature. If the stall test is repeated, do not let the
engine overheat.

• With the vehicle blocked and the parking and service brakes applied, shift to
D (Drive). Then accelerate the engine to wide-open throttle. Stabilize the
converter-out fluid temperature at 255°F (107°C). Record the engine speed.
• Reduce engine speed to idle and shift to N (Neutral).

15
MT1366EN manual.fm Page 16 Friday, April 16, 2004 4:07 PM

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 fluid temperature.

• With the transmission remaining in N (Neutral), run the engine at 1200–1500
rpm for two minutes to cool the fluid.
• At the end of two minutes, record the converter-out fluid temperature.

d. Results

NOTE: Environmental conditions, such as ambient temperature,

altitude, engine accessory loss variations, etc., affect the power input
to the converter. Under such conditions, a stall speed deviation within
a range of ± 150 rpm from specification can be accepted as within
normal range.

• If engine stall speed is more than 150 rpm below the stall speed specified by
the engine manufacturer, an engine problem is indicated, such as need for
tune-up.
• If engine stall speed is more than 150 rpm above specification, a transmission
problem is indicated, such as slipping clutches, cavitation, or torque converter
failure.

16
MT1366EN manual.fm Page 17 Friday, April 16, 2004 4:07 PM

REMOVING S ECTION
TRANSMISSION
FROM VEHICLE
II

2–1. DRAINING TRANSMISSION FLUID

• Drain the transmission before it is removed from the vehicle.
• Park the vehicle on level ground, shift to N (Neutral) and apply the parking or
service brake.
• Start the vehicle engine. Operate the engine until the transmission fluid is
warm. Warm fluid will ensure quicker and better draining.
• Shut off the vehicle engine and remove the drain plug from the oil pan
(disconnect the fill tube on earlier HT 700 Series models). Replace the plug
after fluid has drained. Examine the drained fluid for evidence of water or
debris that indicates failure of internal components.
• On dropbox models, remove the drain plug closest to the bottom of the
dropbox. Drain the fluid and replace the plug. Check for fluid contamination.
• Remove the fill tube if it will interfere during transmission removal.
• Disconnect all other hydraulic lines from the transmission, and allow them to
drain. Cover or plug the lines and openings to keep out dirt.

2–2. DISCONNECTING CONTROLS

CAUTION: Use of an impact wrench requires a means to hold the

selector shaft to prevent internal damage.

• Disconnect or completely remove all controls from the transmission and

position them so they do not interfere with transmission removal.

17
MT1366EN manual.fm Page 18 Friday, April 16, 2004 4:07 PM

NOTE: On models with a splined shift selector shaft, mark the

transmission shift selector lever with a center punch adjacent to the
index mark on the selector shaft before removing the lever, if a mark
is not already present on the lever. Do not use excessive force to
remove the lever. Failure to work the lever carefully from the shaft
will cause internal damage.

• Disconnect all linkage or cables for shifting, shift modulation, hydraulic

retarder, output disconnect controls, parking brake, and speedometer. Remove
the mechanical modulator control. For earlier models, remove the actuator rod
that is free when the modulator is removed (refer to Figure 3–1).
• Disconnect the power takeoff (PTO) from its driven equipment. Disconnect
the PTO controls. Remove the PTO if it will interfere with transmission
removal.
• Disconnect any electrical leads from sensors or other equipment on the
transmission.

2–3. UNCOUPLING FROM DRIVELINE, ENGINE

• Disconnect the vehicle driveline from the transmission output flange or yoke.
Disconnect the input drive flange or yoke (remote mounted). Position the
propeller shaft to avoid interference with transmission removal.
• Figure 2–1 shows a typical arrangement for coupling the engine and
transmission (engine mounted). Remove the drive bolts that secure the
flexplate assembly to the flywheel.

2–4. REMOVING MOUNTING BOLTS

• If transmission mountings support the rear of the engine, place a jack or other
support under the engine.
• Support the transmission securely on a jack, hoist, or other removal
equipment.
• Remove all bolts and supports that attach the transmission to the engine and
vehicle.

18
MT1366EN manual.fm Page 19 Friday, April 16, 2004 4:07 PM

FLYWHEEL
FLYWHEEL HOUSING
STARTER RING GEAR CONVERTER
HOUSING

3.413 in. (86.69 mm)

3.592 in. (91.24 mm)
DRIVE BOLT (12)

FLEXPLATE ASSEMBLY

INNER WEAR PLATE

CRANKSHAFT FLEXPLATE-TO-ADAPTER BOLT

ADAPTER-TO-CRANKSHAFT BOLT
CRANKSHAFT HUB (ADAPTER)

V02376

Figure 2–1. Typical Transmission-to-Engine Coupling

2–5. REMOVING THE TRANSMISSION

• Move the transmission away from the engine until completely clear of the
engine. Remove the adapter ring and/or gasket (if used).
• Raise or lower the transmission as required to remove it from the vehicle.

2–6. REMOVING INPUT AND OUTPUT FLANGES OR YOKES

CAUTION: The use of an impact wrench requires a means to hold the

flange. Failure to hold the flange can cause internal damage to the
transmission.

• When replacing the transmission, it may be necessary to transfer input and

output flanges or yokes to the replacement transmission. If the flanges or
yokes are retained by a large self-locking nut, follow these specific procedures
to remove the nut.

19
MT1366EN manual.fm Page 20 Friday, April 16, 2004 4:07 PM

• Before removing the self-locking nut, check to see if there are any notches cut
into the wrenching flats. If there are five notches, remove the nut and throw it
away.
• If there are less than five notches or none at all, remove dirt and burrs from the
shaft threads. Then loosen the nut until there is about 1⁄16 inch gap between the
nut and flange.
• Check the running torque as the nut is being removed. The first time the nut is
removed (no notches), running torque must be at least 400 lb in. (45 N·m).
Each additional time the nut is removed (one to four notches), running torque
must be at least 300 lb in. (34 N·m). Discard the nut if it does not meet the
running torque limit.

2–7. REBUILD, OVERHAUL INSTRUCTIONS

Refer to the current edition of Service Manual SM1270EN (HT 700) or SM1314EN
(CT 700) for rebuilding or overhauling the transmission.

20
MT1366EN manual.fm Page 21 Friday, April 16, 2004 4:07 PM

PREPARING S ECTION
TRANSMISSION FOR
INSTALLATION
III

3–1. CHECKING FLYWHEEL (ENGINE-MOUNTED MODELS)

• Check the 12-bolt circle on the front of the flywheel. The 1⁄ 2-20 threads must
be undamaged and the holes free of chips or foreign material.
• Check the pilot boss (at center of flywheel) for damage or raised metal that
would prevent free entry into the hub adapter.
• Check the starter ring gear for excessive wear or damage. Check welds that
retain the ring gear (where applicable).
• Check the transmission mounting flange for gasket remnants, raised metal
or dirt.
3–2. INSTALLING BRAKE, OUTPUT FLANGE
• Check the rear oil seal for failure or damage. For replacement instructions
refer to Service Manual SM1270EN (HT 700 Series) or SM1314EN
(CT 700 Series).
• Lubricate the oil seal with high-temperature grease or transmission fluid.
• Check the output flange or yoke for damage or wear. The oil seal contact
surface must be smooth and regular to prevent transmission fluid from leaking
past the seal.
• Install the parking brake assembly. Tighten the bolts to 180 lb ft (240 N·m).
• Install the output flange or yoke. Rotate the flange during installation to avoid
seal lip damage. The brake drum, if it mounts ahead of the flange or yoke,
must be attached before the flange is installed, and its bolts tightened to the
torque recommended by the vehicle manufacturer. Be sure the flange or yoke
hub is seated against the transmission rear bearing.
• The output flange or yoke on straight-through model transmissions is retained
by a large self-locking nut. This nut may be reused up to five times if it meets
running torque requirements during removal (refer to Paragraph 2–6).
• Each time the nut is reused, deeply scribe one of the wrenching flats. This will
allow the mechanic to determine how many times the nut has been used.
• Check the threads on the output shaft and self-locking nut to be sure that they
are clean and free of damage. To prevent thread galling and inaccurate torque
during nut installation, apply molybdenum disulfide grease or transmission
fluid to the threads of the output shaft and nut.

21
MT1366EN manual.fm Page 22 Friday, April 16, 2004 4:07 PM

CAUTION: The use of an impact wrench requires a means to hold

the flange. Failure to hold the flange can cause internal damage to the
transmission.

• Install the self-locking nut and tighten it to 600–800 lb ft (814–1085 N·m).

• Dropbox models with manual disconnect output clutches use two bolts,
shims, and a locking tab to retain the flange and retainer. Refer to Service
Manual SM1270EN (HT 700 Series) or SM1314EN (CT 700 Series) for
shimming procedure and bolt torque.
• If the brake drum mounts behind the flange or yoke, install the drum and
retain it with bolts or nuts (as required). Tighten the bolts or nuts to the torque
recommended by the vehicle manufacturer.

3–3. INSTALLING INPUT FLANGE (REMOTE-MOUNTED MODELS)

• Check the front oil seal for failure or damage. For replacement instructions, refer
to Service Manual SM1270EN (HT 700 Series) or SM1314EN (CT 700 Series).
• Lubricate the oil seal with high-temperature grease or transmission fluid.
• Check the input flange or yoke for damage or wear. The oil seal contact
surface must be smooth and regular to prevent transmission fluid from leaking
past the seal.
• Install the input flange or yoke. Rotate the flange during installation to avoid
seal lip damage. Be sure the flange or yoke is seated against the bearing in the
front of the transmission front cover.
• The input flange or yoke is retained by a large self-locking nut. This nut may
be reused up to five times if it meets running torque requirements during
removal (refer to Paragraph 2–6).
• Each time the nut is reused, deeply scribe one of the wrenching flats. This will
allow the mechanic to determine how many times the nut has been used.
• Check the threads on the input shaft and self-locking nut to ensure that they
are clean and free of damage. To prevent thread galling and inaccurate torque
during nut installation, apply molybdenum disulfide grease or transmission
fluid to the threads of the shaft and nut.

CAUTION: The use of an impact wrench requires a means to hold the

flange. Failure to hold the flange can cause internal damage to the
transmission.

• Install the self-locking nut and tighten it to 450–550 lb ft (610–745 N·m).

22
MT1366EN manual.fm Page 23 Friday, April 16, 2004 4:07 PM

3–4. INSTALLING SHIFT SELECTOR LEVER

Two types of manual shift selector shafts are currently used; the flatted type and the
splined type.

a. Flatted Selector Shafts

• For flatted selector shafts, install the flatted selector lever onto the selector
shaft. The flats in the lever will seat on the tapered flats on the selector shaft
before the lever seats against the shaft shoulder.

CAUTION: Flatted selector shafts that are center-drilled at their

outer ends require an M10 x 1.5-6G nut (metric thread). Shafts that
are undrilled require a 3⁄8-16 nut (standard inch series). Use of the
wrong nut will damage both the shaft and the nut.

• Install the lever retaining nut, finger tight, against the lever.
• Shift the selector to a position two detent “clicks” away from either end.

CAUTION: Overtightening the nut can damage the shaft and/or

lever.

• Hold the lever and tighten the nut to 15–20 lb ft (20–27 N) (Figure 3–1).

SELECTOR
LEVER

ACTUATOR ROD
(LATER MODELS
RETAINED INTERNALLY) L02377

Figure 3–1. Holding Selector Lever For Removal (Installation) of Nut

23
MT1366EN manual.fm Page 24 Friday, April 16, 2004 4:07 PM

b. Splined Selector Shafts

• For splined selector shafts, loosen the clamp bolt in the shift selector lever.
• Locate the punch mark that was put on the outer side of the lever
(Paragraph 2–2) when removed.

CAUTION: Do not drive or force the lever onto the shaft. Internal
damage to the transmission might result.

• Spread the clamp end of the lever, and install the lever so that the punch mark
aligns with the index mark on the end of the transmission selector shaft. Push
the lever on the shaft until the splines fully engage. To prevent internal
damage, do not apply excessive force during lever installation.
• Tighten the clamp bolt to 15–20 lb ft (20–27 N·m) to retain the lever.

3–5. INSTALLING PTO

Space limitation will determine whether the PTO should be installed before or after
the transmission is installed.

• The prescribed backlash for turbine and engine-driven PTO is 0.006–0.029 inch
(0.15–0.74 mm).

CAUTION: Cork or other soft gaskets cannot be used to mount the

PTO. Use only shims or gaskets recommended by the PTO
manufacturer.

• Establish the proper backlash by selecting the proper thickness shims

(gaskets) when mounting the PTO. A PTO that whines is too tight. Gear
clatter indicates too much backlash (too loose).
• To be sure of proper installation, locate the PTO unit driven gear (before
installation) immediately behind the transmission drive gear. Install two
headless guide bolts into the top and bottom of the PTO pad. Install the PTO
unit.
• Gear backlash can be measured through the inspection port provided in some
PTO housings.
• For a PTO mounted at either the top or side of the converter housing, the
prescribed backlash is in addition to that already provided between the drive

24
MT1366EN manual.fm Page 25 Friday, April 16, 2004 4:07 PM

gear in the transmission and its driving gear at the rear of the torque converter
pump. Thus, it is necessary to measure the drive gear-converter pump gear
backlash before installing the PTO.
• On PTO assemblies that require pressure lubrication, install the lubrication
tube fittings. The lubricating fluid comes from the line returning to the
transmission from the oil cooler. Fluid should be directed to the PTO
lubrication circuit after passing through a 0.060 inch (1.52 mm) restriction
(maximum orifice size permitted is 0.110 inch (2.79 mm) for the engine-
driven PTO or 0.032 inch (0.81 mm) restriction for the turbine-driven PTO.)
This restriction is usually provided in the PTO.

CAUTION: PTO units using transmission main pressure to engage the

PTO drive gear must have a positive main pressure shut-off at the
solenoid valve when the PTO is not engaged.

3–6. CONNECTING SHIFT MODULATOR CONTROL

Connect all electrical, pneumatic, or vacuum modulator controls after the
transmission is put into the vehicle. If using mechanical modulator control, refer to
Paragraph 5–9.

3–7. INSTALLING OIL FILL TUBE

If the oil fill tube was removed, install it before the transmission is put into the
vehicle, unless its presence will interfere with transmission installation.

• Install the oil fill tube onto the oil pan boss. If the tube is attached to the oil
pan by a nut, tighten the nut to 90–100 lb ft (123–135 N·m); or, for 4 1⁄ 2 inch
pan models, tighten the nut to 40–50 lb ft (54–68 N·m).

CAUTION: Ensure that the proper length bolts are used. Using bolts
that are too long may cause cracks (leaks) in the pan.

• If the tube is attached by bolts, install the oil fill tube and gasket onto the oil
pan. Install two 5⁄16-24 bolts with lockwashers into the oil pan boss to attach
the tube assembly. Tighten the bolts to 14–18 lb ft (19–24 N·m) for models
with the 6, 7 or 8 1⁄ 2 inch pan. For models with the 4 1⁄ 2 inch pan, tighten the
bolts to 26–32 lb ft (36–44 N·m).

25
MT1366EN manual.fm Page 26 Friday, April 16, 2004 4:07 PM

• Fasten the upper end of the oil fill tube with brackets and bolts as required.
• Install the dropbox fill tube or fluid level indicator into the dropbox
(Figure 1–5).

3–8. FRONT MOUNTING SPACERS

Later transmissions have a reduced width between the mounting pads on the torque
converter housing, and may require spacers between the mounting pads and vehicle
frame mounts.

• SAE grade 8, 5⁄8-11 x 13⁄4 inch bolts are required.

• Install two bolts with lockwashers to retain each spacer. Tighten the bolts to
164–192 lb ft (223–260 N·m).

26
MT1366EN manual.fm Page 27 Friday, April 16, 2004 4:07 PM

PREPARING VEHICLE S ECTION

FOR TRANSMISSION
INSTALLATION
IV

4–1. ENGINE, TRANSMISSION ADAPTATION REQUIREMENTS

• To adapt the transmission to a new installation, ensure that it can be properly
coupled to the engine. The flexplate assembly and certain engine features
must be checked and must be within limits.
• The measuring equipment required includes:
a. 24 inch vernier caliper (Kent-Moore J 26900-25)

b. 2.125–3.500 inch telescoping gauge (Kent-Moore J 26900-24)

c. 2–3 inch outside micrometer (Kent-Moore J 26900-3)

d. Dial indicator and attachments required (Kent-Moore J 5959-01)

to mount (base and posts)

e. 18 inch straight edge*

f. 0–6 inch depth micrometer set

• More detailed information is available in Service Information Letter

60-TR-81 (latest revision), available at Allison distributors or dealers.
• Check the flywheel housing bore diameter. Limits: 20.125–20.133 inch
(511.18–511.38 mm).
• Check the flywheel housing bore runout tolerance. Limit: 0.012 inch
(0.305 mm) T.I.R. maximum.
• Check the flywheel housing face runout tolerance. Limit: 0.012 inch
(0.305 mm) T.I.R. maximum.
• Check the crankshaft hub pilot diameter, or, when used, the hub adapter pilot
diameter. Limits: 2.437–2.439 inch (61.90–61.95 mm).

* The 24 inch vernier caliper can be used as a precision straight edge.

27
MT1366EN manual.fm Page 28 Friday, April 16, 2004 4:07 PM

• Check the crankshaft hub face runout tolerance, or, when used, the installed
hub adapter face squareness. Limit: 0.0005 inch maximum per inch
(0.013 mm per cm) of measured diameter.
• Check the crankshaft hub pilot eccentricity, or, when used, the installed hub
adapter pilot eccentricity. Limit: 0.005 inch (0.13 mm) T.I.R maximum.
• The flatness adjacent to each converter mounting bolt hole measurement is not
a required measurement for HT or CT 700 flexplates.
• Check the flexplate flatness at the converter mounting bolt hole diameter.
Limit: 0.020 inch (0.51 mm) T.I.R. maximum.
• Check the converter axial location. Limits: 3.413–3.592 inch
(86.69–91.24 mm).

4–2. CHECKING FLEXPLATE ASSEMBLY

(ENGINE-MOUNTED MODELS)
• Inspect the flexplate. Replace it if worn or damaged. Examine the flexplate for
pitting, cracks, distortion, and elongated bolt holes.
• Check the engine crankshaft end play. It must be within the limits prescribed
by the engine manufacturer.
• Check the concentricity of the engine crankshaft hub with the flywheel
housing. Refer to engine specifications for runout limits.
• Install the flexplate assembly onto the engine crankshaft, using the bolts and
torque specifications prescribed by the engine or vehicle manufacturer. Refer
to Figure 2–1 for proper position of flexplate, installed.

4–3. CHECKING INPUT DRIVE COMPONENTS

(REMOTE-MOUNTED MODELS)
• Inspect shaft condition. The shaft must not be dented or bent. Welds must be
sound.
• Remove any accumulation of grease and dirt.
• Inspect universal joints, yokes, coupling flanges, and slip-joint splines for
wear or damage.
• Lubricate universal joints and slip joints, using the vehicle manufacturer’s
recommendation for lubricants.

28
MT1366EN manual.fm Page 29 Friday, April 16, 2004 4:07 PM

CAUTION: Misindexing of the driveline can cause failure of the

transmission.

• Check driveline universal joints or slip joints for indexing to conform to

vehicle manufacturer’s specifications.

4–4. CHECKING CHASSIS, DRIVELINE

Inspect the chassis and driveline for the following and correct any faulty conditions
found.

• Broken or worn transmission mounts.

• Worn or missing isolators (rubber mounts).
• Improper or damaged bolts, hardware.
• Cross-frame members, rear-support members.
• Front mounting spaces (some installations have spacers to adapt narrow
converter housing mounts to wider mountings on frame).
• Driveline midship or hanger bearings.
• Driveline yoke slip joints for freedom of movement, wear, lubrication, and
indexing.
• Driveline angles, universal joint indexing, runout and balance for
conformance to manufacturer’s recommendations.
• Auxiliary transmission or transfer case mountings, alignment, flanges or
yokes, backlash, and fluid leaks.
• PTO driven equipment, shafts, and couplings for condition and alignment.

4–5. COOLER, FILTER, AND LINES

Inspect the chassis- and transmission-related plumbing for the following and correct
any faulty conditions found.

• Cooler (heat exchanger)—clean, flush, or replace if cleaning and flushing are

not satisfactory.
• Cooler connecting lines—clean and flush; inspect for deterioration, faulty
connectors, kinks, leaks.
• All lines and fittings for accumulated dirt and grease—clean lines and fittings.

29
MT1366EN manual.fm Page 30 Friday, April 16, 2004 4:07 PM

• All lines for chafing, heat deterioration, and proper routing—replace lines
with high temperature lines, as required, to provide fluid-tight systems.
• O-rings on fittings—replace O-rings (use Viton® O-rings).
• External filter—replace filter element.
• Filter lines—clean and flush; inspect for deterioration, faulty connectors,
kinks.
• Refer to Paragraphs 1–9 and 1–10.

4–6. CHECKING CONTROLS

Inspect the transmission control components on the vehicle for the following, and
correct any faulty conditions found.

• Shift selector control for freedom of movement, frayed or kinked cables,

lubrication, worn rod ends or clevis pins, damaged threads, and proper
routing.
• Mechanical modulator control for freedom of movement, frayed or kinked
cables, lubrication, worn rod ends or clevis pins, damaged threads, and proper
routing.
• Parking brake control for cracks, bends, damaged threads, worn rod ends and
clevis pins.
• PTO control for damage, wear, proper operation, and lubrication.
• Hydraulic retarder control for damage, wear, frayed or kinked cable, worn rod
ends and clevis pins, cotter pins, lubrication, and proper operation.
• Speedometer drive cable for wear, damage, kinks, lubrication, and proper
routing.
• Wiring and related electrical components of signals, sensors or switches for
poor connections, frayed wiring, and damage.
• Capillary tubes or sensors for temperature gauges.
• Fluid pressure gauge tubing for damage, kinks, and proper routing.

30
MT1366EN manual.fm Page 31 Friday, April 16, 2004 4:07 PM

INSTALLING
S ECTION
TRANSMISSION
INTO VEHICLE V
5–1. HANDLING
• Handle the transmission carefully to prevent damage to the transmission and
components in the vicinity of the installation path.
• Be sure that the bottom of the transmission pan is not bent inward. This can
cause the pan to come in contact with the internal suction screen resulting in
starvation of the transmission charging pump.
• Use a hoist or transmission jack that permits precise control of transmission
movements during installation.

5–2. MOUNTING TO ENGINE (ENGINE-MOUNTED MODELS)

• Align one of the twelve bolt holes in the flexplate assembly with the access
opening at the front of the engine flywheel housing.
• Install a headless 1⁄ 2-20 guide bolt into one of the flexplate bolt holes in the
flywheel (Figure 2–1). Align the guide bolt with the flexplate hole at the
access opening.
• Lubricate the center pilot boss with molybdenum disulfide grease.
• Push the transmission toward the engine while guiding the pilot boss on the
flywheel into the flexplate hub (adapter), and the guide bolt into a hole in the
flexplate.
• Seat the transmission squarely against the engine flywheel housing. No force
is required—if interference is encountered, move the transmission away from
the engine and investigate the cause.

CAUTION: The converter housing must be flush against the engine

flywheel housing before tightening any bolts. Do not use the bolts to
seat the housing.

CAUTION: Do not tighten any flywheel bolts until all of the bolts have
been installed finger tight.

31
MT1366EN manual.fm Page 32 Friday, April 16, 2004 4:07 PM

• Align the bolt holes in the converter housing with those in the engine flywheel
housing. Install all of the bolts, finger tight, that attach the transmission to the
engine.
• Tighten four bolts at 90 degree intervals around the converter housing bolt
circle. Then tighten the remaining bolts. Use the torque recommended by the
vehicle or engine manufacturer.
• Remove the guide bolt through the access opening in the engine flywheel
housing. Replace it with a 1⁄ 2-20 x 1 inch self-locking bolt. Tighten the bolt
finger tight at this time.
• While rotating the engine crankshaft, install the eleven remaining
1 ⁄ 2 -20 x 1 inch self-locking bolts into the flywheel, finger tight. When all bolts

are in place, tighten them to 96–115 lb ft (131–156 N·m).

• Install the flywheel housing access cover.

5–3. INSTALLING MOUNTING COMPONENTS

• Install all bolts, washers, spacers, isolators, supports, or cross members
required to support the transmission in the vehicle frame.

CAUTION: Use the type and grade of mounting bolts recommended

by the vehicle manufacturer. The 5⁄8-11 bolts in the converter housing
must have at least 11⁄4 inches (32 mm) thread engagement. The 3⁄4-10
bolts in the rear adapter housing must have at least 11⁄ 2 inches (38 mm)
thread engagement, but must not bottom in the adapter housing.

• Tighten the bolts to the torque recommended by the vehicle manufacturer.

5–4. COUPLING TO ENGINE (REMOTE-MOUNTED MODELS)

• Install (if removed) the input drive shaft components that connect the engine
and transmission.
• Couple the flange or yoke to the flange or yoke at the front of the
transmission. Use the bolts and torque recommended by the vehicle
manufacturer.
• Check the alignment of the transmission with the engine against the vehicle
manufacturer’s specifications.

5–5. COUPLING TO DRIVELINE

• Couple the driveline companion flange or universal joint yoke to the flange
or yoke on the transmission. Use the bolts and torque recommended by the
vehicle manufacturer.

32
MT1366EN manual.fm Page 33 Friday, April 16, 2004 4:07 PM

• Check the universal joint angularity (all joints in driveline) to determine if

they are within the specifications of the vehicle manufacturer.

5–6. CONNECTING COOLER AND FILTER LINES

Figures 5–1 through 5–5 illustrate the different filter and cooler connection
configurations.

ENGINE TO FILTER TO COOLER ENGINE

INPUT (CONVERTER-OUT PLUG
RETARDER TEMPERATURE BULB
HOUSING ADJACENT)

CONVERTER FROM
HOUSING COOLER
FROM FILTER PLUG
LEFT SIDE RIGHT SIDE V02378

Figure 5–1. Earlier Cooler and Filter Connections—Without Engine-Driven

PTO and With Input Retarder

ENGINE 2-BOLT COVER ENGINE

PLUG (EARLIER MODELS)
TO FILTER CONVERTER-OUT
TEMPERATURE BULB

TO
COOLER
FROM FILTER PLUG FROM
LEFT SIDE COOLER RIGHT SIDE V02379

Figure 5–2. Cooler and Filter Connections—Without Engine-Driven PTO

and With Input Retarder

33
MT1366EN manual.fm Page 34 Friday, April 16, 2004 4:07 PM

ENGINE 2-BOLT COVER CONVERTER-OUT

TEMPERATURE BULB
TO FILTER TO COOLER

FROM FILTER FROM COOLER ENGINE

LEFT SIDE RIGHT SIDE V02380

Figure 5–3. Cooler and Filter Connections—Without Engine-Driven PTO and

Without Input Retarder

PTO MOUNT CONVERTER-OUT

TEMPERATURE BULB
TO FILTER
TO COOLER
FROM FILTER

ENGINE FROM COOLER ENGINE

LEFT SIDE RIGHT SIDE V02388

Figure 5–4. Cooler and Filter Connections—With Engine-Driven PTO and

Without Input Retarder

• Connect the external filter and cooler lines to the transmission. Avoid kinks, sharp
bends, twists, and contact with components that will chafe the hydraulic lines.
• Check for proximity to manifolds or exhaust pipes. Excessive heat will hasten the
deterioration of hydraulic lines.
• Be sure all lines are proper size and type recommended. Use new Viton®
O-ring seals where required. Replace any non-Viton® O-rings, regardless of
their condition.
• Tighten the line fittings on the transmission to 50–60 lb ft (68–81 N·m).

34
MT1366EN manual.fm Page 35 Friday, April 16, 2004 4:07 PM

ENGINE CONVERTER-OUT ENGINE

TEMPERATURE BULB PLUG
TO FILTER

PLUG PLUG

TO
FROM FILTER COOLER
CONVERTER INPUT RETARDER HOUSING FROM
HOUSING COOLER
LEFT SIDE RIGHT SIDE V02390

Figure 5–5. Cooler and Filter Connections—With Engine-Driven PTO

and Input Retarder

5–7. CONNECTING SHIFT SELECTOR CONTROL

Proper shift selector adjustment is critical. Improper linkage adjustment can cause
metering of clutch apply fluid, resulting in clutch slippage. The position of the
selector lever (Figure 5–6) directly affects the position of the selector valve. When
the adjustment is correctly made, the linkage to the selector lever retainer pin should
move freely. When there is no free pin movement, it is recommended the linkage be
adjusted as follows.
• At the driver’s position, place shift lever in the R (Reverse) position.
• At the transmission, rotate the selector lever to the R (Reverse) position.
• Align the linkage connector pin to the selector lever. Adjust the linkage if
necessary to obtain a free pin.
• Do the same procedure again, except this time begin with the driver’s shift
selector in the first position.
• Start the engine and move the shift selector to D (Drive). Slowly move the
shift selector toward N (Neutral). Clutch release or engine rpm increase
should be felt before the lever reaches the N (Neutral) slot.
• Move the lever to the R (Reverse) position; then slowly move the shift
selector toward N (Neutral). Clutch release or an engine rpm increase should
be felt before the selector reaches the N (Neutral) slot.
NOTE: For installation of dual-mode shifting or other options, refer
to vehicle service manual and to Preventive Maintenance—Oil Field
Applications PM1772EN.

35
MT1366EN manual.fm Page 36 Friday, April 16, 2004 4:07 PM

RANGE
LEVER FIG. 1 FIG. 2 OPT. 1 OPT. 2
POSITION HT 740 HT 754 HT 750 CT 700 SERIES
HT 747 CR DR
D1 1 1 1 1 1
D2 1–2 1–2 2 2 1–2
D3 1–3 1–3 2–3 2–3 1–3
D4 1–4 1–4 2–4 2–4 1–4
D5 — 1–5 2–5 2–5 1–5
N N N N N N 0.65° WHEN IN
R R R R R R NEUTRAL POSITION
VERTICAL CENTERLINE
INDEXING MARK ON
END OF SHAFT
LOCATED ON CENTERLINE
OF SPLINE TOOTH

8.4°
8.1°
16.2°
24.6°
33.4°
D1 42.3°
CT 700 SERIES
D2
D3
D4 R
D5 N

0.65° WHEN IN
CENTERDRILL ON SHAFT NEUTRAL POSITION
IDENTIFIES REQUIREMENT
FOR METRIC NUT VERTICAL CENTERLINE

8.4°
8.1°
16.2°
24.6°
33.4° HT 700 SERIES
D1 42.3°
D2 FIGURE 2
D3
D1 D4 D5 R
N FIGURE 1
D2
D3 D4 N R

FLATS AS SHOWN INDICATE NEUTRAL POSITION V02392

Figure 5–6. Shift Selector Positions

36
MT1366EN manual.fm Page 37 Friday, April 16, 2004 4:07 PM

5–8. CONNECTING HYDRAULIC INPUT RETARDER CONTROL

• Place the operator’s control at the OFF (disengaged) position.
• Check the hydraulic retarder control valve. The valve is spring-loaded to
retract into the valve body when the retarder is OFF. Lift the valve upward, to
the ON position, to check for full travel—1.5 inches (38 mm) from OFF to
ON position.
• Release the valve, permitting the spring to retract the valve.
• Adjust the linkage so that the rod end or the clevis registers with the pin hole
in the retarder valve. Connect the linkage to the retarder valve, and check the
operation of the valve. The valve must be fully extended when the operator’s
control is at ON; the valve must be fully retracted when the control is at OFF.

CAUTION: Failure to ensure a full OFF stroke will result in low

vehicle power and transmission overheating. Failure to ensure a full ON
stroke will result in less than rated retarder performance (no retarder
complaint).

5–9. CONNECTING MODULATOR CONTROL

• Connect the engine (throttle) end of the modulator cable housing to its
mounting.
• Open the engine throttle fully and check whether the throttle linkage will push
or pull (Figure 5–7) the cable core when the throttle linkage is moving toward
full-throttle position. If it will push the cable core, then push the cable core
until it reaches the end of its travel. If movement of the throttle linkage toward
full-throttle position will pull the cable, then pull the cable to the end of its
travel.
• Adjust the clevis or rod on the cable core until it registers with the hole in the
throttle linkage lever, and the connecting pin can be freely inserted. With the
pin removed, rotate the clevis or rod end one additional turn counterclockwise
(viewing cable core from its end) for pull-type arrangement, or one additional
turn clockwise for push-type arrangement. This will make sure that the
modulator does not prevent the throttle lever from reaching the full ON
position. Install the clevis pin or rod end to connect the throttle linkage and
cable. Tighten the locknut against the clevis or rod end.
• Check the travel of the cable core when the throttle is moved from fully open
to fully closed position. The system is designed to provide a minimum travel
of 1.187 inch (30.15 mm), and a maximum of 1.56 inch (39.6 mm).

37
MT1366EN manual.fm Page 38 Friday, April 16, 2004 4:07 PM

PULL TYPE

PUSH TYPE V02396

Figure 5–7. Current Mechanical Modulators

• Various kinds of modulator controls may be used, but the object of each is to
apply increasing force to the modulator actuator rod as the engine fuel control
is moved from closed to open position. The most common type of control is
the cable-operated mechanical actuator with a lever to vary the force on the
modulator valve. The modulator can usually be converted to use either push or
pull force on the cable when the throttle is opened. Make sure the modulator
controls, when connected to the throttle linkage, provide an increasing force
against the modulator actuator rod in the transmission when the engine
throttle is moved toward the open throttle position.
• Current actuators include a lever that is marked PUSH on one side, and PULL
on the opposite side. When the modulator control cover is removed, the word
PUSH or PULL can be seen and will indicate how the device is assembled.
• Earlier mechanical actuators include a sliding cam (wedge) (Figure 5–8).
When the cover is removed, the position of the cam can be seen. When the
smaller end of the cam is toward the cable housing, the device is the pull type;
when the larger end of the cam is toward the cable housing, the device is the
push type.

38
MT1366EN manual.fm Page 39 Friday, April 16, 2004 4:07 PM

ED
UIR
1.5 in. (38 mm)

EL
REQ
TRAVEL

0 m AV R
AS

m)
T
MID
GTH

(14
in.
LEN

5.5

SEAT
SNAPRING
SPRING

PLUNGER
CONTROL
CABLE
CAM (WEDGE)

PULL-TO-OPERATE ILLUSTRATED L02397

Figure 5–8. Earlier Style Mechanical Modulator

• The conversion of either the lever or cam type to the opposite mode of
operation requires the internal parts to be reassembled. Reverse the positions
of the lever, spring, and thimble in the lever type to convert it (Figure 5–7).
Reverse the cam in the cam type to convert it.
• Be sure the modulator control action is as required.
• Install the O-ring seal onto the modulator control. Coat the O-ring with
oil-soluble grease.
• For earlier models (Figure 5–9), install the modulator actuator rod into the
modulator valve body, through the modulator mounting hole in the
transmission housing.

CAUTION: If the modulator actuator rod is omitted or falls into the

pan during modulator installation (earlier models), the result will be
excessive modulator pressure which will cause the lockup clutch to
engage and stall the engine.

39
MT1366EN manual.fm Page 40 Friday, April 16, 2004 4:07 PM

NEUTRAL START
SWITCH LOCATION

SELECTOR
LEVER SHAFT

ACTUATOR ROD
(LATER MODELS
RETAINED INTERNALLY)
V02398

Figure 5–9. Connection Locations—Left Side

• Install the modulator control into the transmission. Attach the control housing
with the spring clip and the 5⁄16-18 x 3⁄4 inch bolt provided. The convex side of
the formed end of the clip must be toward the transmission, and against the
shoulder of the actuator stem. Tighten the bolt to 13–16 lb ft (18–22 N·m).
• Check the cable routing. Bends must not be of less than 8 inches (200 mm)
radius. Avoid “S” bends. The cable must not be nearer than 6 inches (150 mm)
to the engine exhaust pipe or manifold. The cable must follow the movements
of the throttle linkage. It may be necessary to add a spring to ensure that the
movement occurs smoothly.
• Adjust other types of modulator controls as recommended by the vehicle
manufacturer.
• The cable routing should avoid proximity with heat source such as exhaust
manifolds, mufflers, tailpipes, etc.
• Normal modulator cables will withstand continuous temperatures of 250˚F
(120˚C). Insulation, heat shields, or mechanical linkage actuation may be
necessary if 250˚F (120˚C) is exceeded.

5–10. CONNECTING POWER TAKEOFF CONTROLS

• If not previously installed, mount the PTO on the transmission. Refer to
Paragraph 3–5 for instructions.
• Connect controls to the PTO. Check for proper operation of the controls.
• Check cable or linkage rod routing. Kinks, sharp bends, and proximity of the
cable to exhaust pipes or manifold must be avoided. Rods or linkage must
not rub or interfere with adjacent parts.

40
MT1366EN manual.fm Page 41 Friday, April 16, 2004 4:07 PM

CAUTION: PTOs using main transmission hydraulic pressure to

apply the PTO must have main pressure dead-headed at the valve
when not in use.

• Couple the PTO output to its driven equipment. Check couplings or universal
joints for proper assembly and alignment.

5–11. CONNECTING PARKING BRAKE CONTROL

• Connect and properly adjust the parking brake linkage.
• Adjust the brake shoe-to-drum clearance as specified by the manufacturer.

5–12. CONNECTING OUTPUT DISCONNECT SHAFT CONTROLS

(DROPBOX MODELS)
• Connect and adjust the output disconnect shaft linkage.
• If a manual actuator is used, adjust the linkage to give a crisp detent at the
engaged and disengaged positions—approximately 1.06 inch (26.9 mm).
• If an air actuator is used, the stroke of the cylinder must be controlled to give
a crisp detent at the engaged and disengaged positions.
• Be sure there is no force applied to the shifter shaft when in the fully engaged
or disengaged position.

5–13. CONNECTING SPEEDOMETER DRIVE

• Install the speedometer driven gear assembly into the transmission. Tighten
the body in the transmission rear cover to 45–50 lb ft (61–68 N·m). If no
speedometer drive is provided, be sure the plug is installed to close the hole in
the housing (torque is same as for driven gear body).
• Install the speedometer drive cable onto the driven gear assembly. Tighten the
nut to 50 lb in. (5.65 N·m). Avoid kinks or sharp bends in the cable assembly.
All bends must have a radius of 6 inches (150 mm) or more. No more than
one 90 degree bend is allowed.

5–14. INSTALLING TEMPERATURE AND PRESSURE SENSORS,

ELECTRICAL COMPONENTS
• Install temperature sensors (capillary tube and bulb or thermocouple) into the
converter housing or hydraulic input retarder valve.

41
MT1366EN manual.fm Page 42 Friday, April 16, 2004 4:07 PM

• Refer to Figures 5–1 through 5–5 for various locations. Tighten the 1⁄2 pinch
pipe thread adapter sufficiently to prevent leakage.
• Install the bulb into the adapter and tighten the nut into the adapter.
• Check the capillary tube for interference with parts that might chafe or
damage the tube. Long tubes may require clips or brackets for support.
• Install electrical temperature sensors into the proper openings (refer to
Figures 5–1 through 5–5). Connect electrical leads to the sensors.
• Check that all openings in hydraulic input retarder models that require plugs
are plugged (Figures 5–1 through 5–5).

NOTE: The type and location of the neutral-start switch is optional.

A threaded opening in the left side of the transmission can be used for
installation, if desired (Figure 5–9).

• Install the neutral start switch (if so equipped) into the left side of the
transmission housing (Figure 5–9). The switch must include an aluminum
washer (gasket) approximately 0.090 inch (2.29 mm) thick for earlier
models and 0.030 inch (0.76 mm) thick for later models. Tighten the switch
to 50–60 lb ft (68–81 N·m).
• Connect the wire leads that serve the neutral start switch.
• If the neutral start switch is not mounted at this location, the opening must be
plugged. The plug seats on a rubber-coated washer.
• If so equipped, install the reverse signal switch at the right side of the
transmission housing. Tighten the switch to 48–60 lb in. (5.5–6.7 N·m).
Connect the electrical leads.
• Install and connect other electrical components such as heaters, winterization
equipment, and pressure sensors.
• Install the pressure gauge tubes, if so equipped.
• Check the starting circuit. The starter should operate only when the
transmission shift selector is at the N (Neutral) position.

5–15. FILLING THE HYDRAULIC SYSTEM

• Be sure the hydraulic system is properly filled before starting the engine.
Refer to Section 1, Preventive Maintenance, for capacity information
(Section 1–4c) and cold and hot check procedures (Section 1–4d and e).
• Keep transmission fluid clean.

42
MT1366EN manual.fm Page 43 Friday, April 16, 2004 4:07 PM

SECTION
CHECKS AND
ADJUSTMENTS VI

6–1. ROAD TEST AND VEHICLE OPERATION CHECKLIST

• Refer to Operator’s Manual OM1334EN or OM1475EN for instructions.
• Check the neutral start circuit by trying to actuate the starter at all selector
positions. The starter should operate only when the transmission is in
N (Neutral).
• Check the position of the operators selector lever in each drive range and
neutral. The lever should align with the mark indicating a range (or neutral)
when the transmission is in that range (or neutral).
• Drive the vehicle to determine if the transmission is functioning properly. The
test drive should include a variety of conditions and terrain that will reveal any
deficiency in the transmission operation, or need for adjustment.
• Check the instruments that are associated with the transmission. These
include the speedometer and the transmission temperature gauge.
• Check application and release of the parking brake. Make sure it is not
dragging or heating up while the vehicle is traveling.
• Check operation of the PTO. Refer to the Operator’s Manual for general
operating instructions, or to the vehicle manufacturer’s specific instructions.
• Check the no-load governed speed of the engine. Adjust the governor, if
necessary, to meet the no-load governed speed specified for your particular
engine-transmission match (available from vehicle manufacturer).
• Check operation of the hydraulic input retarder while descending a grade or
slowing on a level road. Stationary vehicles may be checked by revving the
engine to full no-load govern speed in N (Neutral) and applying the retarder.
Note the engine speed will drop significantly.
• To check shift points, refer to Service Manual SM1270EN or SM1314EN for
proper procedure.

43
MT1366EN manual.fm Page 44 Friday, April 16, 2004 4:07 PM

6–2. INSTALLATION CHECKLIST

Use this list after transmission installation. As items are checked, mark
them off this list.

• Proper Torque
❑ Flexplate bolts—96–115 lb ft (130–156 N·m)
❑ Transmission-to-engine bolts—54–65 lb ft (73–88 N·m)
❑ Transmission-to-frame or mounting bolts—164–192 lb ft (222–260 N·m)
❑ Output flange nut—600–800 lb ft (813–1085 N·m)
❑ Companion flange or universal joint bolts*
❑ Manual selector lever nut—15–20 lb ft (20–27 N·m)
❑ PTO mounting bolts—38–50 lb ft (52–68 N·m)
❑ Modulator control retaining bolt—15–20 lb ft (20–27 N·m)
❑ Hydraulic line fittings in transmission housing—40–50 lb ft (54–68 N·m)
❑ Fill tube nut—90–100 lb ft (122–136 N·m)
❑ Speedometer body in rear cover—40–50 lb ft (54–68 N·m)
❑ Speedometer drive cable nut—50 lb in. (6.0 N·m)
❑ Neutral start switch to transmission—50–60 lb ft (68–81 N·m)
❑ Reverse signal switch to transmission—4–5 lb ft (5.42–6.78 N·m)
❑ Parking brake bolts to transmission—164–192 lb ft (222–260 N·m)
❑ Input flange nut—450–550 lb ft (610–745 N·m)
❑ Fluid temperature sensor—16–20 lb ft (22–27 N·m)
• Fluid Cooler, External Filter Lines
❑ Check for leaks
❑ Check for tightness of connections
❑ Check routing
• Linkage
a. Manual selector valve
❑ Adjustment (at all positions)
❑ Ease of movement
❑ Neutral safety switch (start only in N (Neutral))
❑ Shift selector (for freedom of operation)
b. Mechanical modulator control
❑ Adjustment
❑ Ease of operation
❑ Routing
* Tighten to vehicle manufacturer’s recommendations

44
MT1366EN manual.fm Page 45 Friday, April 16, 2004 4:07 PM

• Linkage (cont’d)
c. Parking brake
❑ Adjust for proper clearance
❑ Adjust for full apply
❑ Check for full release
d. Hydraulic input retarder
❑ Adjustment (full open, closed)
❑ Ease of operation
• Driveline
❑ Check for proper indexing of universal joints
❑ Check for proper driveshaft angles
❑ Check differential backlash
❑ Lubricate universals and slip-joints
• Hydraulic System
❑ Recommended fluid (see Paragraph 1–6)
❑ Sufficient fluid in transmission
❑ Dipstick properly marked
❑ Fill cap tight
❑ Fill tube tight at oil pan
❑ Breather clean, free of restriction
❑ Check for fluid leaks during operation
• Power Takeoff
❑ Backlash properly established
❑ Controls connected and operative
❑ Properly coupled to driven equipment
• Instruments, Electrical Components
❑ Speedometer
❑ Fluid temperature gauge
❑ Wiring and electrical connections
❑ Reverse signal switch
❑ Neutral-start switch

45
MT1366EN manual.fm Page 46 Friday, April 16, 2004 4:07 PM

SECTION CUSTOMER
VII SERVICE

7–1. OWNER ASSISTANCE

The satisfaction and goodwill of the owners of Allison transmissions are of primary
concern to Allison Transmission (AT), its distributors, and their dealers.

As an owner of an Allison transmission, you have service locations throughout the

world that are eager to meet your parts and service needs with:

• Expert service by trained personnel

• Emergency service 24 hours a day in many areas
• Complete parts support
• Sales teams to help determine your transmission requirements
• Product information and literature

Normally, any situation that arises in connection with the sale, operation, or service of
your transmission will be handled by the distributor or dealer in your area (check the
telephone directory for the Allison Transmission service outlet nearest you).

Reference the Sales and Service Directory (SA2229EN) for the current listing of
Allison Transmission authorized distributor and service dealers.

We recognize, however, that despite the best intentions of everyone concerned,

misunderstandings may occur. To further assure your complete satisfaction, we have
developed the following three-step procedure to be followed in the event a problem
has not been handled satisfactorily.

Step One—Discuss the problem with a member of management from the

distributorship or dealership. Frequently, complaints are the result of a breakdown
in communication and can quickly be resolved by a member of management. If you
have already discussed the problem with the Sales or Service Manager, contact the
General Manager. All Allison Transmission (AT) dealers are associated with an AT
distributor. If the problem originates with a dealer, explain the matter to a management
member of the distributorship with whom the dealer has his service agreement. The
dealer will provide his AT distributor’s name, address, and telephone number on
request.

46
MT1366EN manual.fm Page 47 Friday, April 16, 2004 4:07 PM

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 Manager’s staff, depending on the nature of your problem.

For prompt assistance, please have the following information available.

• Name and location of authorized distributor or dealer

• Type and make of equipment
• Transmission model number, serial number, and assembly number (if
equipped with electronic controls, also provide the ECU assembly number)
• Transmission delivery date and accumulated miles and/or hours of operation
• Nature of problem
• Chronological summary of unit’s history

Step Three—If you contacted a regional office and you are still not satisfied, present
the entire matter to the Home Office by writing to the following address or
calling the phone number below:

Manager, Warranty Administration – PF9

Allison Transmission
P.O. Box 894
Indianapolis, IN 46206-0894
Phone: 1-800-524-2303

The inclusion of all pertinent information will assist the Home Office in expediting the
matter. If an additional review by the Home Office of all the facts involved indicates
that some further action can be taken, the Regional Office will be advised.

When contacting the Regional or Home Office, please keep in mind that ultimately the
problem will likely be resolved at the distributorship or dealership utilizing their
facilities, equipment, and personnel. Therefore, it is suggested the above steps be
followed in sequence when experiencing a problem.

Your purchase of an Allison Transmission product is greatly appreciated, and it is our

sincere desire to assure complete satisfaction.

47
MT1366EN manual.fm Page 48 Friday, April 16, 2004 4:07 PM

7–2. 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.
If you are unable to obtain these publications from your Allison distributor, please
contact:

SGI, Inc.
Attn: Allison Literature Fulfillment Desk
8350 Allison Avenue
Indianapolis, IN 46268
TOLL FREE: 888-666-5799
INTERNATIONAL: 317-471-4995

Table 7–1. Service Literature

HT 740, 740FS, 747, CT, CLT,
754CR, 750DR, CLBT 750,
750DR (DB) 754 (DB)
*Operator’s Manual OM1334EN OM1475EN
OM1772EN**
Service Manual SM1270EN SM1314EN
*Parts Catalog PC1268EN PC1315EN
Parts Catalog CD-ROM CD1268EN CD1315EN
Technician’s Guide/Inspection Analysis GN2033EN GN2033EN
Troubleshooting Manual TS1838EN N/A
Worldwide Sales and Service Directory SA2229EN SA2229EN
* Also Available On The Internet At www.allisontransmission.com
** Preventive Maintenance Oil Field Applications

48
MT1366EN 200403 www.allisontransmission.com Printed in USA 200404