operator's manual 1000 and 2000 product...

OM3063EN

MT4108EN

Operator’s Manual1000 and 2000Product Families

Allison TransmissionOn-Highway

Operator’sManual

2003 JUNERev. 1 2004 JULY

OM3063EN

1000 and 2000 Product Families

Printed in USA Copyright © 2007 Allison Transmission, Inc.

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Allison Transmission, Inc.P.O. Box 894 Indianapolis, Indiana 46206-0894www.allisontransmission.com

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TABLE OF CONTENTS

INTRODUCTIONKEEPING THAT ALLISON ADVANTAGE . . . . . . . . . . . . . . . . . . . . . . . . 7A BRIEF DESCRIPTION OF THE ALLISON 1000 AND 2000 PRODUCTFAMILIES TRANSMISSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10ELECTRONIC CONTROL SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . 10TORQUE CONVERTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11PLANETARY GEARS AND CLUTCHES . . . . . . . . . . . . . . . . . . . . . . . . 11COOLER CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

SHIFT SELECTORSDESCRIPTION OF AVAILABLE TYPES . . . . . . . . . . . . . . . . . . . . . . . . . 17OPERATION OF THE SHIFT SELECTOR. . . . . . . . . . . . . . . . . . . . . . . . 17RANGE SELECTION—ALL 1000 AND 2000 PRODUCT FAMILIESTRANSMISSIONS WITH P (PARK) POSITIONS. . . . . . . . . . . . . . . . . . . 20RANGE SELECTION—ALL 1000 AND 2000 PRODUCT FAMILIESTRANSMISSIONS WITHOUT P (PARK) POSITIONS. . . . . . . . . . . . . . . . 24RANGE SELECTION—ALL 2000 PRODUCT FAMILY TRANSMISSIONS WITHAUTO-APPLY PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28RANGE SELECTION—ALL 2000 PRODUCT FAMILY TRANSMISSIONSWITHOUT AUTO-APPLY PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . 32

DRIVING TIPSMAXIMUM VEHICLE LOADING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36PREVENT MAJOR PROBLEMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36TURNING ON/OFF THE VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . . 36ACCELERATOR CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37PRIMARY/SECONDARY SHIFT SCHEDULES. . . . . . . . . . . . . . . . . . . . 37KICKDOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38OUTPUT SPEED INDICATOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38RANGE INHIBIT(ED) LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38CHECK TRANS OR MALFUNCTION INDICATOR LIGHT . . . . . . . . . . . . 38SHIFT INHIBITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39USING THE ENGINE TO SLOW THE VEHICLE. . . . . . . . . . . . . . . . . . . 41RANGE PRESELECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41REVERSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43REFUSE PACKER STEP SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . 43TWO-SPEED AXLE (Some 1000 and 2000 Product Families Applications). . . . 43DRIVING ON SNOW OR ICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43ROCKING OUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44OPERATING TEMPERATURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44HIGH FLUID TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

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PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45PARK PAWL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46PARKING/LEAVING VEHICLE WITH ENGINE RUNNING . . . . . . . . . . . . 47TOWING OR PUSHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49SURGING NATURAL GAS ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . 49

POWER TAKEOFFPOWER TAKEOFF (PTO) SYSTEMS. . . . . . . . . . . . . . . . . . . . . . . . . . 50CONVERTER-DRIVEN POWER TAKEOFF (PTO). . . . . . . . . . . . . . . . . . 50SPLIT-SHAFT POWER TAKEOFF (PTO). . . . . . . . . . . . . . . . . . . . . . . . 53

CARE AND MAINTENANCEPERIODIC INSPECTIONS AND CARE. . . . . . . . . . . . . . . . . . . . . . . . . 55IMPORTANCE OF PROPER TRANSMISSION FLUID LEVEL. . . . . . . . . . . 56TRANSMISSION FLUID CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56KEEPING FLUID CLEAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60FLUID RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60TRANSMISSION FLUID AND FILTER CHANGE INTERVALS . . . . . . . . . . 62TRANSMISSION FLUID CONTAMINATION . . . . . . . . . . . . . . . . . . . . . 64COOLER FLUSHING PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . 65TRANSMISSION FLUID AND FILTER CHANGE PROCEDURE. . . . . . . . . 66VENT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

DIAGNOSTICSDIAGNOSTIC CODES AND TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . 69

CUSTOMER SERVICEOWNER ASSISTANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70SERVICE LITERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72ALLISON TRANSMISSION DISTRIBUTORS . . . . . . . . . . . . . . . . . . . . . 73ALLISON TRANSMISSION REGIONAL OFFICES. . . . . . . . . . . . . . . . . . 75

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TRADEMARK USAGEThe following trademarks are the property of the companies indicated:

• DEXRON® is a registered trademark of the General Motors Corporation.

• TranSynd™ is a trademark of Castrol Ltd.

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WARNINGS, CAUTIONS, NOTES

IT IS YOUR RESPONSIBILITY to be completely familiar with the warningsand cautions described in this handbook. It is, however, important to understandthat these warnings and cautions are not exhaustive. Allison Transmission couldnot possibly know, evaluate, and advise the service trade of all conceivable waysin which service might be done or of the possible hazardous consequences of eachway. The vehicle manufacturer is responsible for providing information related tothe operation of vehicle systems (including appropriate warnings, cautions, andnotes). Consequently, Allison Transmission has not undertaken any such broadevaluation. Accordingly,ANYONE WHO USES A SERVICE PROCEDUREOR TOOL WHICH IS NOT RECOMMENDED BY ALLISONTRANSMISSION OR THE VEHICLE MANUFACTURER MUST first bethoroughly satisfied that neither personal safety nor equipment safety will bejeopardized by the service methods selected.

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

Three types of headings are used in this manual to attract your attention. Thesewarnings and cautions advise of specific methods or actions that can result inpersonal injury, damage to the equipment, or cause the equipment to becomeunsafe.

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

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

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

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KEEPING THAT ALLISON ADVANTAGE

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Allison 1000 and 2000 Product Familiesprovide many advantages for the driverwho must “stop and go” or change speeds frequently. Driving is easier, safer, andmore efficient.

The 1000 and 2000 Product Familiestransmissions are rugged and designed toprovide long, trouble-free service. This handbook will help you gain maximumbenefits from yourALLISON -equipped vehicle.

INTRODUCTION

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A BRIEF DESCRIPTION OF THE ALLISON 1000 AND 2000PRODUCT FAMILIES TRANSMISSIONSThe 1000 and 2000 Product Families transmissions are fully automatic,torque-converter driven, electronically controlled transmissions best suited forlight-medium duty, on-highway applications. Each transmission series containsfeatures which have been designed for specific vocational needs.

• 1000 Product Family—These models are best suited for light dutyon-highway applications. The 1000 Product Family transmissions have parkpawls.

• 2000 Product Family—These models are best suited for single-axle mediumduty on-highway applications. The 2000 Product Family includestransmissions with park pawls and transmissions that do not have parkpawls.

The park pawl exists but cannot be engaged in some vehicle configurations using1000 and 2000 Product Families transmissions (e.g., some rear engine vehicleswith air brakes). For these configurations, theP (Park) position is not used.

A provision to mount a Power Takeoff (PTO) is available on all models. The PTOdrive gear is optional.

All models have up to five forward ranges and one reverse. All clutches arehydraulically-actuated, spring-released, and have automatic compensation for wear.Gearing is helical type, arranged in planetary sets. Electronic controls provideautomatic gear selection in each drive range and automatic engagement of thetorque converter (lockup) clutch.

ELECTRONIC CONTROL SYSTEMThe 1000 and 2000 Product Families control system consists of five majorcomponents connected by customer-furnished wiring harnesses. These componentsare:

• Transmission Control Module (TCM)

• Engine throttle position sensor or direct electronic communication ofthrottle information

• Engine, turbine, and output speed sensors

• NSBU switch

• Control valve module

The control valve module contains solenoids and a pressure switch module toposition and monitor control valve operation. The pressure switch module alsocontains a thermistor to monitor sump fluid temperature. The throttle positionsensor (or engine-to-transmission communication link), speed sensors, pressureswitch module, and NSBU switch transmit information to the TCM. The TCMprocesses this information and then sends signals to actuate specific solenoidslocated on the control valve module in the transmission. These solenoids control

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both oncoming and offgoing clutch pressures to provide closed-loop shift controlby matching rpm during a shift to a previously established desired profile that isprogrammed into the TCM.

The 1000 and 2000 Product Families electronic control system has the “adaptiveshifting” feature. Adaptive shifting helps optimize shift quality by monitoringcritical characteristics of clutch engagement and making on-going adjustments toimprove subsequent shifts. The transmission shift calibration is based on severaldifferent types of shifts, e.g., full throttle, part throttle, closed throttle—upshifts,downshifts, etc. Each shift is associated with specific speed and throttle positionparameters. In order to optimize each type of shift for normal driving, shiftcontrols must experience operation and shifting in a wide variety of operatingconditions.

A “drive in” period under varied driving conditions is required before theAdaptive Controls can be expected to optimize each and every shift. In general,shift quality will begin to converge to their “adapted” level after five typical shiftsof a particular shift type.

TORQUE CONVERTERThe torque converter consists of three elements—pump, turbine, and stator. Thepump is the input element and is driven directly by the engine. The turbine is theoutput element and is hydraulically driven by the pump. The stator is the reaction(torque multiplying) element. When the pump turns faster than the turbine, thetorque converter is multiplying torque. When the turbine approaches the speed ofthe pump, the stator starts to rotate with the pump and turbine. When this occurs,torque multiplication stops and the torque converter functions as a fluid coupling.

All 1000 and 2000 Product Families torque converters contain a torque converter(lockup) clutch. When engaged, this clutch causes the torque converter pump andturbine to be locked together, thus enabling them to rotate in unison at enginespeed. This condition, commonly referred to as “torque converter clutchoperation,” thus provides direct drive through the transmission. This type ofoperation maximizes engine braking and enhances fuel economy. The torqueconverter (lockup) clutch is regulated by the shift controls to engageautomatically. The torque converter clutch releases at lower speeds or when theTCM detects conditions requiring it to be released. The torque converter clutchcontains a damping mechanism which reduces the transmittal of engine-inducedtorsional vibrations into and beyond the transmission.

PLANETARY GEARS AND CLUTCHESA series of three helical planetary gear sets and shafts provides the mechanicalgear ratios and direction of travel for the vehicle. The planetary gear sets arecontrolled by five multiplate clutches that work in pairs to produce up to five

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forward speeds and one reverse speed. The clutches are applied and releasedhydraulically in response to electronic signals from the TCM to the appropriatesolenoids.

COOLER CIRCUITThe transmission fluid is cooled by a remote-mounted oil cooler. The bottom ofthe transmission torque converter housing provides for the direct mounting of acontrol main filter and includes two ports to facilitate the attachment of the oilcooler lines.

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DESCRIPTION OF AVAILABLE TYPESThe 1000 and 2000 Product Families transmissions use lever-type shift selectors.The shift positions on the shift selector can vary according to the shift selectorinstalled.

OPERATION OF THE SHIFT SELECTORThe shift selector is used by the operator to select the following ranges.

• Park (P) for transmissions with park pawls

• Auto-Apply Parking Brake (PB) for vehicles with automatically engagedparking brakes

• Reverse (R)

• Neutral (N)

• Drive (D)*

• Fourth Range (4)**

• Third Range (3)**

• Second Range (2)**

• First Range (1)

* The shift selector position representing this gear range may be labeled “5” (forthe highest gear in the range), “OD” (for Overdrive), “D” (for the normal Driveposition), or “1–5” (for the complete gear range).

** In calibrations with five forward ranges, one of these selector positions will notbe available.

Ranges are selected by moving the lever to the desired selector position (P, PB,R, N, D, 4, 3, 2, or 1). Five speed transmission models have five forward ranges,first through fifth. Four speed models have four forward ranges, first throughfourth. When a forward range has been selected, the transmission automaticallyupshifts through each range. As the vehicle slows, the transmission will downshiftautomatically through each range.

SHIFT SELECTORS

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The following tables list the shift selector positions and corresponding ranges forall 1000 and 2000 Product Families transmissions.

All 1000 and 2000 Product Families With P (Park) Position

ShiftSelectorPosition Range



P (Park) Neutral* P (Park) Neutral* P (Park) Neutral*R (Reverse) Reverse R (Reverse) Reverse R (Reverse) ReverseN (Neutral) Neutral N (Neutral) Neutral N (Neutral) NeutralD (Drive)** 1–5 D (Drive)** 1–5 D (Drive)** 1–5

(1–4)***4 (Fourth) 1–4 4 (Fourth) 1–4 3 (Third) 1–33 (Third) 1–3 2 (Second) 1–2 2 (Second) 1–21 (First) 1 1 (First) 1 1 (First) 1* With Park Pawl engaged

** The shift selector position representing this gear range may be labeled “5” (for the highest gearin the range), “OD” (for Overdrive), “D” (for the normal Drive position), or “1–5” (for thecomplete gear range)

*** 1–4 in Trailering Mode or 4 Speed Calibration

All 1000 and 2000 Product Families Without P (Park) Position




R (Reverse) Reverse R (Reverse) Reverse R (Reverse) ReverseN (Neutral) Neutral N (Neutral) Neutral N (Neutral) NeutralD (Drive)** 1–5 D (Drive)** 1–5 D (Drive)** 1–5

(1–4)***4 (Fourth) 1–4 4 (Fourth) 1–4 3 (Third) 1–33 (Third) 1–3 2 (Second) 1–2 2 (Second) 1–21 (First) 1 1 (First) 1 1 (First) 1** The shift selector position representing this gear range may be labeled “5” (for the highest gear

in the range), “OD” (for Overdrive), “D” (for the normal Drive position), or “1–5” (for thecomplete gear range)


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All 2000 Product Family With Auto-Apply Parking Brake

Shift SelectorPosition Range



PB(Auto-ApplyParking Brake)

Neutral* PB(Auto-ApplyParking Brake)

Neutral* PB(Auto-ApplyParking Brake)

Neutral*

R (Reverse) ReverseR (Reverse) ReverseR (Reverse) ReverseN (Neutral) Neutral N (Neutral) Neutral N (Neutral) NeutralD (Drive)** 1–5 D (Drive)** 1–5 D (Drive)** 1–5

(1–4)***4 (Fourth) 1–4 4 (Fourth) 1–4 3 (Third) 1–33 (Third) 1–3 2 (Second) 1–2 2 (Second) 1–21 (First) 1 1 (First) 1 1 (First) 1* With Auto-Apply Parking Brake engaged

** The shift selector position representing this gear range may be labeled “5” (for the highest gearin the range), “OD” (for Overdrive), “D” (for the normal Drive position), or “1–5” (for thecomplete gear range).


All 2000 Product Family Without Auto-Apply Parking Brake




R (Reverse) Reverse R (Reverse) Reverse R (Reverse) ReverseN (Neutral) Neutral N (Neutral) Neutral N (Neutral) NeutralD (Drive)** 1–5 D (Drive)** 1–5 D (Drive)** 1–5

(1–4)***4 (Fourth) 1–4 4 (Fourth) 1–4 3 (Third) 1–33 (Third) 1–3 2 (Second) 1–2 2 (Second) 1–21 (First) 1 1 (First) 1 1 (First) 1** The shift selector position representing this gear range may be labeled “5” (for the highest gear

in the range), “OD” (for Overdrive), “D” (for the normal Drive position), or “1–5” (for thecomplete gear range).


There are several features of the 1000 and 2000 Product Family transmissions thatcan inhibit transmission shifting. See the SHIFT INHIBITS paragraph of thismanual.

With an Allison-equipped vehicle, selecting the right moment to upshift ordownshift during changing road and traffic conditions is not necessary. The Allison

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1000 and 2000 Product Families transmission does it for you. However,knowledge of the ranges and when to select them will make vehicle control andyour job even easier.

RANGE SELECTION—ALL 1000 AND 2000 PRODUCTFAMILIES TRANSMISSIONS WITH P (PARK) POSITIONS

ALL TRANSMISSIONS WITH P (PARK) POSITION

WARNING: For vehicles containing 1000 and 2000 ProductFamilies transmissions, follow this procedure each time theoperator’s station will be unoccupied with the engine running.

• Bring the vehicle to a complete stop using the service brake.• Make sure the engine is at low idle rpm.• Put the transmission inP (Park).• Engage the park pawl by slowly releasing the service brake.• If a parking brake is present, apply the parking brake. Make

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

engaged.• Chock the wheels and take any other steps necessary to keep

the vehicle from moving.If this procedure is not followed, the vehicle can moveunexpectedly and cause injury and/or property damage.

P UseP (Park) for the following.

• to turn on or turn off the engine

• to check vehicle accessories

• to operate the engine at idle for longer than five minutes

• for stationary operation of the power takeoff (if your vehicleis equipped with a PTO)

This position places the transmission inN (Neutral) and engagesthe park pawl.

WARNING: R (Reverse) may not be obtained due to an activeinhibitor. Always apply the service brakes when selectingR (Reverse) to prevent unexpected vehicle movement andbecause a service brake inhibit can be present. Always be surethat “R” is not flashing wheneverR (Reverse) is selected.Check for active diagnostic codes ifR (Reverse) is not attained.

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WARNING: To help avoid injury and/or property damagecaused by unexpected vehicle movement, do not make shiftsfrom R (Reverse) toN (Neutral) without applying the servicebrakes, parking brake, or emergency brake. SelectingN (Neutral)does not apply vehicle brakes unless an auxiliary system to applya parking brake is installed.

CAUTION: Do not idle inR (Reverse) for more thanfive minutes. Extended idling inR (Reverse) can causetransmission overheating and damage. Always selectP (Park)whenever time at idle exceeds five minutes.

R R (Reverse) is used to back the vehicle. Completely stop the vehicleand let the engine return to idle before shifting from a forwardrange toR (Reverse) or fromR (Reverse) to a forward range. Thereverse warning signal is activated when the shift selector is in thisposition.

WARNING: To help avoid injury or property damage caused byunexpected vehicle movement, do not make shifts to or fromN (Neutral) without manually or automatically applying anappropriate vehicle brake.

WARNING: DO NOT allow the vehicle to “coast” inN (Neutral). There is no engine braking inN (Neutral). Youcould lose control of the vehicle, causing property damage orpersonal injury. Coasting in neutral can cause severe transmissiondamage.

N This position places the transmission inN (Neutral). Used forstarting the engine and stationary operation.

WARNING: D (Drive) and other forward ranges can not beobtained due to an active inhibitor. The range selected can not beobtained, resulting in unexpected vehicle movement. To helpavoid injury and/or property damage, always apply the servicebrakes when selectingD (Drive) or other forward ranges. Checkfor the RANGE INHIBIT(ED) light or theCHECK TRANSlight.

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WARNING: To help avoid injury and/or property damagecaused by unexpected vehicle movement, do not make shiftsfrom a forward range toN (Neutral) without applying the servicebrakes, parking brake, or emergency brake. SelectingN (Neutral)does not apply vehicle brakes unless an auxiliary system to applya parking brake is installed.

CAUTION: Do not idle inD (Drive) or any forward range formore than five minutes. Extended idling inD (Drive) can causetransmission overheating and damage. Always selectP (Park)whenever time at idle exceeds five minutes.

NOTE: Turn off the vehicle HIGH IDLE switch, if present, beforeshifting from N (Neutral) toD (Drive) or R (Reverse).D (Drive) orR (Reverse) will not be attained unless the shift is made with theengine at idle.

D* UseD (Drive) for normal driving. The transmission will initiallyattain first range whenD (Drive) is selected. As vehicle speedincreases, the transmission will upshift automatically through eachavailable range up to4 (FOURTH ) or 5 (FIFTH ). As the vehicleslows, the transmission will downshift automatically.* The shift selector position representing this gear range may belabeled “5” (for the highest gear in the range), “OD” (forOverdrive), “D” (for the normal Drive position), or “1–5” (for thecomplete gear range).

WARNING: The transmission incorporates a hold feature toprohibit upshifting above the range selected during normaldriving. For downhill operation, select a lower transmissionrange. If the engine governed speed is exceeded in the heldrange, however, the transmission will upshift to the next higherrange to prevent engine damage. To avoid injury and/or propertydamage due to loss of vehicle control, use the vehicle brakes toprevent exceeding engine governed speed in the held range.

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WARNING: To avoid loss of control, use a combination ofdownshifting, braking, and other retarding devices. Downshiftingto a lower transmission range increases engine braking and canhelp you maintain control. The transmission has a feature toprevent automatic upshifting above the lower range selected.However, during downhill operation, if engine governed speed isexceeded in the lower range, the transmission will upshift to thenext higher range to prevent engine damage. This will reduceengine braking and could cause a loss of control. Apply thevehicle brakes or other retarding device to prevent exceedingengine governed speed in the lower range selected.

4*3*

Use4 (FOURTH ) or 3 (THIRD ) for city traffic and braking onsteep downgrades.* 3 for shift selectors withP,R,N,D,3,2,1Actual ranges available depend on programming by vehiclemanufacturer.

3*2*

Use3 (THIRD ) or 2 (SECOND) for heavy city traffic and brakingon steeper downgrades.* 3 for shift selectors withP,R,N,D,4,3,1Actual ranges available depend on programming by vehiclemanufacturer.

1 Use1 (FIRST) range for the following.

• when pulling through mud and deep snow

• when maneuvering in tight spaces

• while driving up or down very steep gradesFirst range provides the vehicle with its maximum driving torqueand maximum engine braking effect.

23

RANGE SELECTION—ALL 1000 AND 2000 PRODUCTFAMILIES TRANSMISSIONS WITHOUT P (PARK)POSITIONS

1000 AND 2000 PRODUCT FAMILIES TRANSMISSIONS WITHOUTP (PARK) POSITION

WARNING: For vehicles containing 1000 and 2000 ProductFamilies transmissions withoutP (Park) positions, each time youpark the vehicle or leave the operator’s station with the enginerunning, do the following.

• Bring the vehicle to a complete stop using the service brake.• Ensure that the engine is at low idle rpm.• Put the transmission inN (Neutral).• Apply the emergency brake and/or parking brake and make

sure they are properly engaged.• If the operator’s station will be unoccupied with the engine

running, chock the wheels and take any other steps necessaryto keep the vehicle from moving.

If the procedure is not followed, the vehicle may move suddenlyand cause injury and/or property damage.



CAUTION: Do not idle inR (Reverse) for more thanfive minutes. Extended idling inR (Reverse) can causetransmission overheating and damage. Always selectN (Neutral)whenever time at idle exceeds five minutes.

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N UseN (Neutral) for the following.





WARNING: D (Drive) and other forward ranges can not beobtained due to an active inhibitor. The range selected can notbe obtained, resulting in unexpected vehicle movement. To helpavoid injury and/or property damage, always apply the servicebrakes when selectingD (Drive) or other forward ranges. Checkfor the RANGE INHIBIT(ED) light or theCHECK TRANSlight.

25



CAUTION: Do not idle inD (Drive) or any forward range formore than five minutes. Extended idling inD (Drive) can causetransmission overheating and damage. Always selectN (Neutral)whenever time at idle exceeds five minutes.




26



4*3*

Use4 (FOURTH ) or 3 (THIRD ) for city traffic and braking onsteep downgrades.* 3 for shift selectors withR,N,D,3,2,1Actual ranges available depend on programming by vehiclemanufacturer.

3*2*

Use3 (THIRD ) or 2 (SECOND) for heavy city traffic and brakingon steeper downgrades.* 3 for shift selectors withR,N,D,4,3,1Actual ranges available depend on programming by vehiclemanufacturer.





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RANGE SELECTION—ALL 2000 PRODUCT FAMILYTRANSMISSIONS WITH AUTO-APPLY PARKING BRAKE

2000 PRODUCT FAMILY TRANSMISSIONS WITH AUTO-APPLYPARKING BRAKE

WARNING: For vehicles containing 2000 Product Familytransmissions withoutPB (Auto-Apply Parking Brake) selectorposition, follow this procedure each time the operator’s stationwill be unoccupied with the engine running.

• Bring the vehicle to a complete stop using the service brake.• Make sure the engine is at low idle rpm.• Put the transmission inPB (Auto-Apply Parking Brake).

Make sure the parking brake is properly engaged.• Apply the emergency brake and make sure it is properly

engaged.• Chock the wheels and take any other steps necessary to keep


PB UsePB (Auto-Apply Parking Brake) for the following.





This position places the transmission inN (Neutral) and engagesthe parking brake.


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CAUTION: Do not idle inR (Reverse) for more thanfive minutes. Extended idling inR (Reverse) can causetransmission overheating and damage. Always selectPB (Auto-Apply Parking Brake) whenever time at idle exceedsfive minutes.




N This position places the transmission inN (Neutral). Used forstarting the engine and stationary operation.

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WARNING: D (Drive) and other forward ranges can not beobtained due to an active inhibitor. The range selected can not beobtained, resulting in unexpected vehicle movement. To helpavoid injury and/or property damage, always apply the servicebrakes when selectingD (Drive) or other forward ranges. Checkfor the RANGE INHIBIT(ED) light or theCHECK TRANSlight.


CAUTION: Do not idle inD (Drive) or any forward range formore than five minutes. Extended idling inD (Drive) can causetransmission overheating and damage. Always selectPB (Auto-Apply Parking Brake) whenever time at idle exceedsfive minutes.



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4*3*

Use4 (FOURTH ) or 3 (THIRD ) for city traffic and braking onsteep downgrades.* 3 for shift selectors withPB,R,N,D,3,2,1Actual ranges available depend on programming by vehiclemanufacturer.

3*2*

Use3 (THIRD ) or 2 (SECOND) for heavy city traffic and brakingon steeper downgrades.* 3 for shift selectors withPB,R,N,D,4,3,1Actual ranges available depend on programming by vehiclemanufacturer.





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RANGE SELECTION—ALL 2000 PRODUCT FAMILYTRANSMISSIONS WITHOUT AUTO-APPLY PARKINGBRAKE

2000 PRODUCT FAMILY TRANSMISSIONS WITHOUT AUTO-APPLYPARKING BRAKE

WARNING: For vehicles containing 2000 Product Familytransmissions withoutPB (Auto-Apply Parking Brake) selectorposition, follow this procedure each time the operator’s stationwill be unoccupied with the engine running.

• Bring the vehicle to a complete stop using the service brake.• Make sure the engine is at low idle rpm.• Put the transmission inN (Neutral), apply the parking brake,

emergency brake, and make sure they are properly engaged.• Chock the wheels and take any other steps necessary to keep




CAUTION: Do not idle inR (Reverse) for more thanfive minutes. Extended idling inR (Reverse) can causetransmission overheating and damage. Always selectN (Neutral)whenever time at idle exceeds five minutes.

32





N UseN (Neutral) for the following.





WARNING: D (Drive) and other forward ranges can not beobtained due to an active inhibitor. The range selected can notbe obtained, resulting in unexpected vehicle movement. To helpavoid injury and/or property damage, always apply the servicebrakes when selectingD (Drive) or other forward ranges. Checkfor the RANGE INHIBIT(ED) light or theCHECK TRANSlight.

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CAUTION: Do not idle inD (Drive) or any forward range formore than five minutes. Extended idling inD (Drive) can causetransmission overheating and damage. Always selectN (Neutral)whenever time at idle exceeds five minutes.




34



4*3* Use4 (FOURTH ) or 3 (THIRD ) for city traffic and braking onsteep downgrades.* 3 for shift selectors withR,N,D,3,2,1Actual ranges available depend on programming by vehiclemanufacturer.

3*2* Use3 (THIRD ) or 2 (SECOND) for heavy city traffic and brakingon steeper downgrades.* 3 for shift selectors withR,N,D,4,3,1Actual ranges available depend on programming by vehiclemanufacturer.





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MAXIMUM VEHICLE LOADING

WARNING: Operation with excessive loads can cause transmissiondamage and unexpected vehicle movement. To help avoid injury,property damage and/or transmission damage, do not exceed thefollowing.

• For 1000 Product Family and 2000 Product Family transmissionswith park pawls, do not exceed 11 800 kg (26,000 lb) GCW or theOEM vehicle rating, whichever is less.

• For 2000 Product Family transmissions, do not exceed 13 600 kg(30,000 lb) GCW or the OEM rating, whichever is less.

PREVENT MAJOR PROBLEMSMinor problems can be kept from becoming major problems if you notify anAllison Transmission distributor or dealer when any of these conditions occur.

• Shifting feels abnormal

• Transmission leaks fluid

• Unusual transmission-related sounds (changes in sound caused by normalengine thermostatic fan cycling, while climbing a long grade with a heavyload, have been mistaken for transmission-related sounds)

• CHECK TRANS light or RANGE INHIBIT(ED) light comes onfrequently

TURNING ON/OFF THE VEHICLEBefore turning on or off the engine, the driver must verify that one of thefollowing ranges has been selected and engaged.

• P (Park)

• PB (Auto-Apply Parking Brake)

• N (Neutral) if P (Park) orPB (Auto-Apply Parking Brake) is not available

The vehicle should not start unless these ranges have been selected. If the vehiclestarts in any other range, seek service immediately.

DRIVING TIPS

36

Transmission operation at cold ambient temperatures may require preheating orthe use of a lower viscosity transmission fluid. See the FLUID RECOMMENDA-TIONS paragraph in this manual.

Even when the engine is warm and capable of full-throttle output, the transmissionshould not be taken out ofP (Park),PB (Auto-Apply Parking Brake), orN (Neutral) for at least thirty seconds to allow for buildup of transmission fluidpressure.

ACCELERATOR CONTROL

WARNING: To avoid injury or property damage caused by suddenmovement of the vehicle, do not make shifts fromN (Neutral) to aforward range orR (Reverse) when the throttle is open. The vehicle willlurch forward or rearward and the transmission can be damaged. Avoidthis condition by making shifts fromN (Neutral) to a forward range orR (Reverse) only when the throttle is closed and service brakes areapplied.

The position of the accelerator pedal influences the timing at which automaticshifting occurs. When the pedal is fully depressed, upshifts will occurautomatically at high engine speeds. A partially depressed position of the pedalwill cause the upshifts to occur at lower engine speeds. An electronic throttleposition signal tells the TCM how much the operator has depressed the pedal.Excessive throttle position may inhibit the directional shift.

PRIMARY/SECONDARY SHIFT SCHEDULESThe points at which shifts occur depend upon predetermined speeds and otheroperating conditions. A transmission “shift calibration” includes several sets ofshift points which may be used according to current or anticipated operatingconditions. Some shift schedules may be inhibited as a result of operatingconditions, such as engine or transmission fluid temperature. Shift schedules maybe changed through selection of a remote (usually dash-mounted) switch—whichis typically associated with a change in anticipated vehicle operation.

The TCM includes the capacity for two separate and distinct shift calibrations(customer-selectable), one for use in “Primary Mode” of operation and one in“Secondary Mode.”

• Primary—This shift schedule is typically used for all normal vehicleoperations.

• Secondary—This is an alternate shift schedule that the TCM uses uponrequest. Not all vehicles will be equipped with a secondary shift. Therequest can be interlocked with a vehicle component, or beoperator-controlled via a dash-mounted switch.

37

Your vehicle may have a dash-mounted light that illuminates when the secondarymode is active.

KICKDOWNSome vehicles have a “kickdown” feature that allows the operator to choosebetween an “Economy” primary shift schedule and “Performance” secondary shiftschedule. The throttle pedal will have a detent feel when full-throttle is achievedusing “Economy” shift points. When the operator “steps through” this detent, thefunction is activated and “Performance” shift points are achieved.

OUTPUT SPEED INDICATORYour vehicle may contain a light or other indicator that is activated when a presetoutput speed has been exceeded in the vehicle, transmission, or auxiliaryequipment. The output speed may occur in either the forward or reverse direction.This indicator may be used to alert the operator that a specific overspeed conditionhas occurred or to indicate the attainment of a minimum or maximum operatingspeed.

RANGE INHIBIT(ED) LIGHTThe red or amberRANGE INHIBIT(ED) warning light is located on or near theshift selector. The purpose of this indicator is to alert the operator thattransmission operation is being inhibited and that range shifts being requested bythe operator may not occur. When certain operating conditions are detected by theTCM, the controls will command the transmission to be locked in the rangecurrently in use. If the torque converter clutch is applied when the condition isdetected, the clutch will be disengaged concurrently with the activation of theRANGE INHIBIT(ED) light.

Each time the engine is started, theRANGE INHIBIT(ED) light will illuminate,then turn off after two seconds. If the light does not illuminate during ignition, orif the light remains on after ignition, the transmission system should be checkedimmediately.

For the conditions under which shift inhibits occur, see the SHIFT INHIBITSparagraph in this manual.

CHECK TRANS OR MALFUNCTION INDICATOR LIGHTThe red or amberCHECK TRANS light or Malfunction Indicator Light (MIL) ofsome type is located on the dash panel. For vehicles which are compliant toindustry On Board Diagnostics II (OBD II) requirements, an MIL Light will bepresent. For vehicles which are not compliant to industry OBD II requirements, aCHECK TRANS light will be present.

38

Each time the engine is started, theCHECK TRANS or MIL light willilluminate, then turn off after two seconds. If the light does not illuminate duringignition, or if the light remains on after ignition, the transmission system shouldbe checked immediately.

Illumination of theCHECK TRANS light at any time after start-up indicates thata problem has been detected. The TCM will register a diagnostic code and shiftsmay be restricted. Depending upon the severity of the problem, operation maycontinue in order to reach service assistance. The TCM may not respond to shiftselector requests since upshifts and downshifts may be restricted and directionchanges may not occur.

Illumination of the MIL Light at any time after start-up may indicate a problemwith the engine or transmission.

SHIFT INHIBITSThe transmission control system will inhibit shifting to protect the transmissionfrom some types of abusive operation, in response to diagnostic trouble codes, andto satisfy transmission feature/option requirements. These shift inhibits fall withinthe following types.

• Above-idle neutral-to-range shifts

• Forward/reverse directional shifts

• Transmission problems

• Auxiliary equipment operation

Above-Idle Neutral-to-Range Shifts.


Above-idle (greater than 900 rpm) shifts fromN (Neutral) toR (Reverse) orN (Neutral) to a forward range are normally inhibited (except in emergencyvehicles or some other type of specialized equipment).

When these shifts are inhibited, theRANGE INHIBIT(ED) light will illuminate.See the RANGE INHIBIT(ED) LIGHT paragraph in this manual for furtherinformation.

39

Forward/Reverse Directional Shifts.


Forward/reverse directional changes are typically not permitted if appreciableoutput shaft speed is detected.

When these shifts are inhibited, theRANGE INHIBIT(ED) light will illuminate.See the RANGE INHIBIT(ED) LIGHT paragraph in this manual for furtherinformation.

Transmission Problems.Lights such as aRANGE INHIBIT(ED) , CHECKTRANS, and a flashingPRNDL display will be illuminated when thetransmission detects a problem. An illuminatedRANGE INHIBIT(ED) light or aflashingPRNDL display indicates that the TCM has locked the transmission intoa forward range orR (Reverse). Shifts fromN (Neutral)-to-D (Drive),N (Neutral)-to-R (Reverse) and directional shifts will be inhibited. The lockedrange allows the vehicle to reach service assistance. The transmission will remainlocked until the problem has been corrected. With the exception of diagnostictrouble code (DTC) U2105, theCHECK TRANS light will be illuminated whenthe TCM has registered a DTC. When a U2105 is registered, theCHECKTRANS light may not be illuminated in earlier models. Depending upon theseverity of the problem, operation may continue to allow the vehicle to reachservice assistance by locking the transmission in the range currently in use. TheTCM may inhibit upshifts, downshifts and directional change shifts. See theDIAGNOSTIC CODES AND TOOLS paragraph in this manual for furtherinformation.

An illuminated Malfunction Indicator Light (MIL) may indicate a problem withthe transmission or engine.

See the RANGE INHIBIT(ED) LIGHT and CHECK TRANS ORMALFUNCTION INDICATOR LIGHT paragraphs in this manual for furtherinformation.

Auxiliary Equipment Operation. The TCM will prevent shifts fromP (Park),PB (Auto-Apply Parking Brake), orN (Neutral)-to-range when auxiliaryequipment is in operation (e.g., a wheelchair lift). For some vehicles such asbuses, shifts fromP (Park),PB (Auto-Apply Parking Brake), orN (Neutral)-to-range will be prevented unless the brake pedal is depressed.

40

USING THE ENGINE TO SLOW THE VEHICLE

WARNING: The transmission incorporates a hold feature to prohibitupshifting above the range selected during normal driving. For downhilloperation, select a lower transmission range. If the engine governedspeed is exceeded in the held range, however, the transmission willupshift to the next higher range to prevent engine damage. To avoidinjury and/or property damage due to loss of vehicle control, use thevehicle brakes to prevent exceeding engine governed speed in the heldrange.

WARNING: To avoid loss of control, use a combination ofdownshifting, braking, and other retarding devices. Downshifting to alower transmission range increases engine braking and can help youmaintain control. The transmission has a feature to prevent automaticupshifting above the lower range selected. However, during downhilloperation, if engine governed speed is exceeded in the lower range, thetransmission will upshift to the next higher range to prevent enginedamage. This will reduce engine braking and could cause a loss ofcontrol. Apply the vehicle brakes or other retarding device to preventexceeding engine governed speed in the lower range selected.

To use the engine as a braking force, select the next lower range. If the vehicle isexceeding the maximum speed for this range, use the service brakes and/or otherretarding devices to slow the vehicle. When a lower speed is reached, the TCMwill automatically downshift the transmission. Engine braking provides goodspeed control for going down grades. When the vehicle is heavily loaded, or thegrade is steep, it may be desirable to preselect a lower range before reaching thegrade. If engine-governed speed is exceeded, the transmission will upshiftautomatically to the next range.

CAUTION: Using the retarder or engine brake on wet or slippery roadsmay cause loss of traction on the drive wheels — your vehicle mayslide out of control. To help avoid injury or property damage, turn theretarder or engine brake enable to OFF when driving on wet or slipperyroads.

RANGE PRESELECTIONRange preselection means selecting a lower range to match driving conditions youencounter or expect to encounter. Learning to take advantage of preselected shiftswill give you better control on slick or icy roads and on downgrades.

41

Downshifting to a lower range increases engine braking. The selection of a lowerrange often prevents cycling between that range and the next higher range on aseries of short up-and-down hills.

NOTE: Preselecting during normal operation may result in reduced fueleconomy.

Manual range downshifts will not occur until a calibration value of output speed isreached. When a range downshift is manually selected and the transmission outputspeed is above the calibration value, the transmission will stay in the range it wasin even though a lower range was requested. Apply the vehicle service brakes orsome retarding device to reduce the transmission output speed to the calibrationvalue and then the shift to the lower range will occur.

Two shift schedules are used with range preselection: hold upshift and preselectdownshift.

Hold Upshift. This shift schedule keeps the transmission from shifting above theselected range. This shift schedule permits upshifts to occur if an engineoverspeed condition could result by the transmission remaining (by operatorselection) in a range lower than its highest range. When the hold feature isactivated, transmission upshift points occur at engine speeds which are higher thannormal upshifts in order to “hold” the transmission from upshifting beyond thecurrent range.

WARNING: The transmission incorporates a hold feature to prohibitupshifting above the range selected during normal driving. For downhilloperation, select a lower transmission range. If the engine governedspeed is exceeded in the held range, however, the transmission willupshift to the next higher range to prevent engine damage. To avoidinjury and/or property damage due to loss of vehicle control, use thevehicle brakes to prevent exceeding engine governed speed in the heldrange.

Preselect Downshift.This shift schedule is used when the driver preselects alower range. The operator may preselect any range belowD (Drive) on the shiftselector at any time. When a range has been “preselected” in this manner, shiftpoints to and from ranges above the preselected range are higher than the normalshift points. The transmission will downshift when an engine overspeed conditionwill not result after the shift. Shifts below the preselected range are not affected.

42

REVERSEPutting the transmission intoR (Reverse) may activate vehicle back-up lightsand/or reverse warning devices.

To achieveREVERSE range in some European transit and tour buses, aninstrument panel-mounted switch must be pressed simultaneously with theR (Reverse) shift selector button.

REFUSE PACKER STEP SWITCHWhen personnel are on the rear step of a refuse packer, the transmission willoperate inFIRST andNEUTRAL only.

• An operator request to upshift beyondFIRST or to shift toR (reverse) isignored by the TCM.

• If the transmission is inR (reverse), the TCM will cause the transmission toshift to NEUTRAL .

• If the transmission is in a forward range higher than 1 (FIRST), the TCMwill invoke “preselect downshifts” untilFIRST is attained.

TWO-SPEED AXLE (Some 1000 and 2000 Product FamiliesApplications)The two-speed axle may be shifted while the vehicle is moving. However, theaxle or vehicle manufacturer’s recommendations should be followed for shiftingthe axle. It is recommended that axle shifts be made with the transmission in thehighest range, or vehicle stopped, to prevent a transmission shift from coincidingwith an axle shift.

DRIVING ON SNOW OR ICEHere is where all of your ability as a professional driver comes into focusregardless of what transmission you have. If possible, reduce your speed andselect a lower range before you lose traction. Select the range that will not exceedthe speed you expect to maintain. Accelerate or decelerate very gradually toprevent losing traction. It is very important to slow gradually when a lower rangeis selected. It is important that you reach the lower range selected beforeattempting to accelerate. This will avoid an unexpected downshift duringacceleration.

NOTE: If ABS is activated, the lockup clutch is automaticallydisengaged.

43

ROCKING OUT


CAUTION: If the wheels are stuck and not turning, do not apply fullpower for more than 30 seconds in eitherD (Drive) or R (Reverse). Fullpower for more than 30 seconds under these conditions will cause thetransmission to overheat. If the transmission overheats, shift toN (Neutral) and operate the engine at 1200–1500 rpm until it cools(2–3 minutes).

If the vehicle is stuck in deep sand, snow, or mud, it may be possible to rock itout. Shift toD (Drive) and apply steady, light throttle (never full throttle). Whenthe vehicle has rocked forward as far as it will go, apply and hold the vehicleservice brakes. Allow the engine to return to idle; then selectR (Reverse). Releasethe brakes and apply a steady, light throttle and allow the vehicle to rock inR (Reverse) as far as it will go. Again, apply and hold the service brakes andallow the engine to return to idle. This procedure may be repeated inD (Drive)andR (Reverse) if each directional shift continues to move the vehicle a greaterdistance. Never makeN (Neutral)-to-D (Drive) or directional shift changes whenthe engine rpm is above idle.

OPERATING TEMPERATURESTo ensure proper operation of the transmission, adhere to the following minimumand maximum transmission operating temperatures.

Sump, minimum continuous 40°C (100°F)Sump, maximum intermittent 121°C (250°F)To cooler, maximum intermittent 149°C (300°F)

Your transmission may have a converter-out transmission temperature gauge nearthe “to-cooler” port on the transmission converter housing.

44

HIGH FLUID TEMPERATURE

CAUTION: Always selectP (Park),PB (Auto-Apply Parking Brake),or N (Neutral) whenever time at idle exceeds five minutes. Extendedidling in any other ranges can cause transmission overheating anddamage.

CAUTION: Sustained use of the parking brake with the engine runningand the transmission in range can cause an overheating failure of thetransmission. The vehicle can contain a buzzer or dash-mounted light toalert the operator when the ignition switch is “ON”, the parking brake isapplied, and the transmission selector is in range.

CAUTION: The engine should never be operated for more than30 seconds at full throttle with the transmission in range and the outputstalled. Prolonged operation of this type will cause the transmission fluidtemperature to become excessively high and will cause severe overheatdamage to the transmission.

Your vehicle may have a dash indicator or other alarm that turns on when thetransmission sump temperature or to-cooler temperature exceeds specified limits.

If the transmission overheats during normal operations, do the following.

• Check the fluid level in the transmission. See the CARE ANDMAINTENANCE section of this manual.

• Safely stop the vehicle and check the cooling system. If it appears to befunctioning properly, run the engine at 1200–1500 rpm with thetransmission inN (Neutral). This should reduce the transmission and enginetemperatures to normal operating levels in 2 or 3 minutes. If temperaturesdo not decrease, reduce the engine rpm.

• If high temperature in either the engine or transmission persists, stop theengine and have the overheating condition investigated by maintenancepersonnel.

PARKING BRAKEFor shift selectors with aPB (Auto-Apply Parking Brake) position, selectingPB (Auto-Apply Parking Brake) places the transmission inNEUTRAL andautomatically engages the parking brake. For shift selectors without aPB (Auto-Apply Parking Brake) position, the parking brake must be manuallyengaged. Your vehicle may have an indicator light that illuminates when theparking brake is applied.

45

CAUTION: Do not apply the transmission-mounted parking brake withthe vehicle in motion. Transmission and/or driveline damage can result.In the event of a dynamic brake apply, recheck the torque of all brakemounting bolts to verify the integrity of the mount.

CAUTION: Sustained use of the parking brake with the engine runningand the transmission in range can cause an overheating failure of thetransmission. The vehicle can contain a buzzer or dash-mounted light toalert the operator when the ignition switch is “ON”, the parking brake isapplied, and the transmission selector is in range.

PARK PAWLA park pawl is standard on 1000 Product Family transmissions and some 2000Product Family transmissions. The park pawl effectively grounds the transmissionoutput shaft, thereby preventing rotation of the driveline. Provided the vehicle isstationary, selectingP (Park) on the shift selector places the transmission inNEUTRAL and engages the park pawl. The park pawl exists but cannot beengaged in some vehicle configurations using 1000 and 2000 Product Familiestransmissions (e.g., some rear engine vehicles with air brakes). For theseconfigurations, theP (Park) position is not used.

WARNING: To help avoid injury and/or property damage caused byunexpected vehicle movement, do not attempt to engageP (Park) withthe vehicle in motion (2 km/hr (1 mph) or higher). If you attempt toengageP (Park) with the vehicle in motion (2 km/hr (1 mph) or higher),the park pawl will ratchet, will not engage, and will not hold thevehicle. Repeated park pawl ratcheting can cause transmission damage.

WARNING: If the vehicle has four-wheel-drive and the transfer case isin Neutral, the vehicle can be free to roll even if theP (Park) position isselected. To avoid injury and/or property damage caused by unexpectedmovement of the vehicle, be certain that the transfer case is in “high”drive range, not Neutral, whenever the vehicle is parked.

46

WARNING: If the vehicle is equipped with a two-speed axle ortwo-speed transfer case which is engaged in “low”, even very lowvehicle speeds can produce appreciable transmission output shaft speed.Even the slightest vehicle motion can deter engagement of the park pawlin such cases. To help avoid injury and/or property damage caused byunexpected vehicle movement, be certain that the axle or transfer case isin “high” drive range whenever the vehicle is parked and the park pawlis engaged.

Torque Lock. If the vehicle is parked on an incline andP (Park) is properlyengaged, the weight of the vehicle may generate an excessive amount of torque onthe park pawl in the transmission. In this situation, it may be difficult to shift thetransmission out of theP (Park) position. This condition is commonly called“torque lock.”

To drive a vehicle with torque lock, do the following.

1. Push the vehicle uphill a small amount to release the pressure on the parkpawl and permit the shift out ofP (Park).

2. Shift the transmission out ofP (Park) while applying the service brakes.

3. Release the parking brake.

PARKING/LEAVING VEHICLE WITH ENGINE RUNNING

WARNING: For vehicles containing 1000 and 2000 Product Familiestransmissions with park pawls, follow this procedure each time theoperator’s station will be unoccupied with the engine running.

• Bring the vehicle to a complete stop using the service brake.• Make sure the engine is at low idle rpm.• Put the transmission inP (Park).• Engage the park pawl by slowly releasing the service brake.• If a parking brake is present, apply the parking brake. Make sure

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

engaged.• Chock the wheels and take any other steps necessary to keep the

vehicle from moving.If this procedure is not followed, the vehicle can move unexpectedlyand cause injury and/or property damage.

47

WARNING: For vehicles containing 1000 and 2000 Product Familiestransmissions withoutP (Park) positions, each time you park the vehicleor leave the operator’s station with the engine running, do the following.

• Bring the vehicle to a complete stop using the service brake.• Make sure the engine is at low idle rpm.• Put the transmission inN (Neutral).• Apply the emergency brakes and/or parking brake and make sure

they are properly engaged.• If the operator’s station will be unoccupied with the engine

running, chock the wheels and take any other steps necessary tokeep the vehicle from moving.

If this procedure is not followed, the vehicle can move unexpectedlyand cause injury and/or property damage.

WARNING: For vehicles containing 2000 Product Family transmissionwith PB (Auto-Apply Parking Brake) selector position, follow thisprocedure each time the operator’s station will be unoccupied with theengine running.

• Bring the vehicle to a complete stop using the service brake.• Make sure the engine is at low idle rpm.• Put the transmission inPB (Auto-Apply Parking Brake). Make




WARNING: For vehicles containing 2000 Product Family transmissionwithout PB (Auto-Apply Parking Brake) selector position, follow thisprocedure each time the operator’s station will be unoccupied with theengine running.


emergency brake, and make sure they are properly engaged.If this procedure is not followed, the vehicle can move unexpectedlyand cause injury and/or property damage.

48

TOWING OR PUSHING

CAUTION: Failure to lift the driving wheels off the road, disconnectthe driveline, or remove the axle shafts before pushing or towing cancause serious transmission damage.

The engine cannot be started by pushing or towing. Before pushing or towing avehicle, lift the drive wheels off the road, disconnect the driveline, or remove theaxle shafts from the drive wheels. When the axle shafts are removed, be sure tocover the wheel openings to prevent loss of lubricant and entry of dust and dirt.An auxiliary air supply will usually be required to release the vehicle brakesystem.

SURGING NATURAL GAS ENGINES

NOTE: Engine surging or engine speed cycling may occur on naturalgas powered equipment. This condition typically occurs when thetransmission is being operated in a hold position with throttle appliedand the engine speed above full load engine governed speed. Surgingmay also occur at closed and part throttle. This condition is an enginecharacteristic and NOT a transmission concern.

49

POWER TAKEOFF (PTO) SYSTEMSThree types of PTO systems may be used with the 1000 and 2000 ProductFamilies transmissions.

• Transmission-Mounted Converter-Driven PTO—A transmission-mountedconverter-driven PTO drive provides both an infinitely-variable PTO driveratio and a protective hydraulic cushion against abrupt loading/unloading(during “converter mode” operation) and engine-driven PTO speed control(during “torque converter clutch mode” operation).

• Split-Shaft PTO—A split-shaft PTO, a chassis-mounted component, istypically used in applications which require full engine power beingavailable to either propel the vehicle or to power auxiliary equipmentthrough the PTO drive—but not both simultaneously. In both cases, thetransmission output shaft delivers power to the split-shaft transfer case. Thesplit-shaft transfer case is then shifted to deliver this power to either thedriveline or PTO drive.

• Flywheel-Driven PTO—A flywheel-driven PTO, often called a “sandwichPTO,” mounts between the engine and transmission. The PTO is normallydriven directly by the engine.

CONVERTER-DRIVEN POWER TAKEOFF (PTO)The following pertains to Transmission-Mounted Converter-Driven PTOs only.

PTO Configuration. The PTO is mounted on the left and/or right side of thetransmission housing. The PTO drivetrain consists of a large drive gear in thetransmission, an idler gear arrangement, and a smaller driven gear in the PTO.The drive gear is integral to the transmission rotating clutch housing, whichrotates at the same speed as the torque converter turbine. With this driveconfiguration, the PTO rotates in the same direction as the engine.

Two types of transmission-mounted PTOs may be used with these transmissionmodels.

• A constant-drive PTO is used in applications which require full-time PTOoperation. The PTO driven gear is in constant mesh with the drive gear andcannot be disengaged.

• A clutch drive PTO is used in applications which require only part-timeoperation of the PTO. For clutch drive PTOs, the following applies: 1) the

POWER TAKEOFF

50

engagement/disengagement provision is facilitated by a hydraulic clutchmechanism in the PTO assembly; 2) the PTO can be engaged or disengagedat any time (except at engine speeds that exceed drive speed limits imposedon the driven equipment).

PTO Engagement — Sliding Gear PTOs.

CAUTION: Do not use or install a sliding gear PTO where the slidinggear meshes directly with the PTO drive gear. The PTO drive gear canbe damaged when the sliding gear slides into the PTO drive gear,producing metal particles that can cause transmission damage.

NOTE: “Manual shift PTOs”—units which are engaged/disengaged tothe PTO drive gear in the transmission through use of a manual(“sliding gear”) mechanism—are not compatible with the design of thesetransmission models.

PTO Engagement — Manual Shift PTO.Manually shifted (Cable, Electrical,Air shifted) PTOs that engage internally inside the PTO can be used.

WARNING: If you leave the vehicle and the engine is running, thevehicle can move unexpectedly and you or others could be injured. DONOT leave the vehicle with the engine running unless you have takenall of the following precautions:

• Shift the transmission toN (Neutral) orP (Park)• Make sure that the engine is at low idle (500–800 rpm)• Apply the park brake or emergency brake and make sure it is

properly engaged• Chock the wheels and take any other steps necessary to keep the

vehicle from moving

On automatic transmissions, the gears in the transmission turn when thetransmission is in neutral, therefore, gears clashing will occur if the PTO is shiftedinto range or out of range at this time.

With Converter Driven Gear:

1. Engine idle. With the operator seated in the driver’s seat and whileactivating the vehicle’s brake, shift transmission level into any of the drivepositions. (This will stop transmission gear from turning.)

2. Shift PTO into or out of range.

3. If the PTO does not engage release the PTO to the disengage position, shiftthe transmission to neutral and repeat the above steps from step A.

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4. Shift the transmission into park or neutral. (This will start transmissiongears turning.) If you hear a grinding or ratcheting sound turn PTO off andrepeat these procedures from step A.

PTO Engagement — Clutch Driven.The PTO will engage only when the PTOswitch is on, the throttle position is low, and engine speed and output speed arewithin user-specified limits. Your vehicle may have a light on the dash thatilluminates when the PTO is engaged.

CAUTION: Do not exceed the engagement and operational speed limitsimposed on the driven equipment during the operation of the PTO.Exceeding the speed limits produces high hydraulic pressure in the PTOthat can damage the PTO components. Consult the vehiclemanufacturer’s literature for these speed limits.

CAUTION: Some vehicles “creep” in range at low vehicle speeds whilemaintaining a specified engine speed for PTO operation (e.g., paintstripers and feedlot trucks). DO NOT use the vehicle brakes to controlvehicle speed during PTO operation. Use ONLY throttle to control bothengine and vehicle speed when the transmission is in reverse or aforward range. Applying BOTH brakes and throttle will cause thetransmission to overheat. Extended operation at elevated temperatureswill damage the transmission.

PTO Operation. The transmission operates in either converter mode or torqueconverter clutch mode. In converter mode, the torque converter (lockup) clutch isnot engaged and the PTO is driven through the torque converter, producing atorque at the PTO drive gear that is always greater than the input torque. In torqueconverter clutch mode, the torque converter (lockup) clutch is engaged, the PTOdrivetrain is driven at a speed proportional to the engine speed.

The PTO drive is normally in continuous converter mode operation when thetransmission is inP (Park),PB (Auto-Apply Parking Brake), andR (Reverse).Torque converter clutch operation inN (Neutral) is available for someapplications. If the PTO is used with the transmission inD (Drive) or anotherforward range, transmission shifts (both converter/torque converter clutch modeshifts and shifts between gears) are based on the automatic shift sequence of thetransmission shift controls. PTO drive gear speed will be affected each time a shiftoccurs.

With the vehicle stopped and the engine at idle, PTO output speed is dependentupon the transmission gear selection.

• If the transmission is inD (Drive) or R (Reverse), the PTO output speed iszero.

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• If the transmission is inN (Neutral),P (Park), orPB (Auto-Apply ParkingBrake), the PTO output will rotate slowly.

In some vehicles, the transmission will shift intoN (Neutral) regardless of theshift selector position under the following conditions.

• the PTO is enabled

• the transmission output speed is near zero

• the throttle position is near zero

To reselect a range, the operator must shift into N (Neutral), then shift to thedesired range.

CAUTION: Do not exceed the engagement and operational speed limitsimposed on the driven equipment during the operation of the PTO.Exceeding the speed limits produces high hydraulic pressure in the PTOthat can damage the PTO components. Consult the vehiclemanufacturer’s literature for these speed limits.

CAUTION: When the PTO disengages due to overspeed, the PTO willautomatically re-engage at a user-specified speed, which is typicallyrelatively low. The resultant re-engagement shock could cause damageto a high-inertia PTO system.

PTO Overspeed Protection.All 1000 and 2000 Product Families-equippedvehicles with PTO enable have engagement and operational speed limitsprogrammed into the TCM to help protect PTO equipment. The PTO willdeactivate when operational speeds (either engine or transmission output) areexceeded. When the PTO is disengaged due to overspeed, the PTO will beautomatically re-engaged at a user specified speed, which is typically relativelylow. After the speed has been reduced, the operator may manually engage thePTO by repeating the engagement process.

SPLIT-SHAFT POWER TAKEOFF (PTO)For many split-shaft PTOs, holding the transmission in direct drive at all enginespeeds is desirable. In this manner, the automatic range shifts are eliminated,thereby eliminating rapid torque changes which would occur at the drivenequipment during a shift in the transmission. Such a condition, for instance, couldcreate an undesirable pressure surge (and directional control problem) at thenozzle-end of a fire hose.

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NOTE: Unlike most Allison on-highway transmission models, the 1000and 2000 Product Family transmissionsdo not have a controls provisionwhich supports this type of split-shaft PTO application. The output of asplit-shaft PTO driven by these models will, therefore, be subjected totransmission range shifts and will experience rapid speed and torquechanges with each occurrence.

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PERIODIC INSPECTIONS AND CARE

Transmission Inspection.

CAUTION: Do not spray steam, water, or cleaning solution directly atthe vent assembly (breather). Spraying steam, water, or cleaning solutionat the vent assembly can force the water or cleaning solution into thetransmission and contaminate the transmission fluid. Seal all openingsand the vent assembly (breather) before spraying steam, water, orcleaning solutions on the transmission.

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

• loose bolts — transmission and mounting components

• fluid leaks — repair immediately

• loose, dirty, or improperly adjusted throttle sensor or shift selector linkage

• damaged or loose hoses

• worn, frayed, or improperly routed electrical harnesses

• worn or frayed electrical connections

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

• clogged or dirty vent assembly

Vehicle Inspection.Check the vehicle cooling system occasionally for evidence oftransmission fluid which would indicate a faulty oil cooler.

CARE AND MAINTENANCE

55

Welding.

CAUTION: When welding on the vehicle:• DO NOT WELD on the vehicle without disconnecting all control

system wiring harness connectors from the TCM.• DO NOT WELD on the vehicle without disconnecting TCM

battery power and ground leads.• DO NOT WELD on any control components.• DO NOT CONNECT welding cables to any control components.• PROTECT CONTROL COMPONENTS FROM SPARKS AND

HEAT DURING WELDING.

A label describing on-vehicle welding precautions is available from yourauthorized Allison service dealer and should be installed in a conspicuous place. Avehicle used in a vocation that requires frequent modifications or repairs involvingwelding must have an on-vehicle welding label. Refer to ST2067EN.

IMPORTANCE OF PROPER TRANSMISSION FLUID LEVELTransmission fluid cools, lubricates, and transmits hydraulic power. Alwaysmaintain proper fluid level. If fluid level is too low, the torque converter andclutches do not receive an adequate supply of fluid and the transmission overheats.If the level is too high, the fluid aerates—causing the transmission to shifterratically and overheat. Fluid may be expelled through the vent assembly ordipstick tube when the fluid level is too high.

TRANSMISSION FLUID CHECK

WARNING: For vehicles containing 1000 and 2000 Product Familiestransmissions with park pawls, follow this procedure each time theoperator’s station will be unoccupied with the engine running.

• Bring the vehicle to a complete stop using the service brake.• Make sure the engine is at low idle rpm.• Put the transmission inP (Park).• Engage the park pawl by slowly releasing the service brake.• If a parking brake is present, apply the parking brake. Make sure

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



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WARNING: For vehicles containing 1000 and 2000 transmissionswithout P (Park) positions, each time you park the vehicle or leave theoperator’s station with the engine running, do the following.

• Bring the vehicle to a complete stop using the service brake.• Make sure the engine is at low idle rpm.• Put the transmission inN (Neutral).• Apply the emergency brakes and/or parking brake and make sure

they are properly engaged.• If the operator’s station will be unoccupied with the engine

running, chock the wheels and take any other steps necessary tokeep the vehicle from moving.

If this procedure is not followed, the vehicle can move unexpectedlyand cause injury and/or property damage.

WARNING: For vehicles containing 2000 Product Family transmissionwith PB (Auto-Apply Parking Brake) selector position, follow thisprocedure each time the operator’s station will be unoccupied with theengine running.

• Bring the vehicle to a complete stop using the service brake.• Make sure the engine is at low idle rpm.• Put the transmission inPB (Auto-Apply Parking Brake). Make




WARNING: For vehicles containing 2000 Product Family transmissionswithout PB (Auto-Apply Parking Brake) selector position, follow thisprocedure each time the operator’s station will be unoccupied with theengine running.


emergency brake, and make sure they are properly engaged.If this procedure is not followed, the vehicle can move unexpectedlyand cause injury and/or property damage.

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Fluid Check Procedure.Clean all dirt from around the end of the fluid fill tubebefore removing the dipstick. Do not allow dirt or foreign matter to enter thetransmission. Dirt or foreign matter in the hydraulic system may cause undue wearof transmission parts, make valves stick, and clog passages. Check the fluid levelusing the following procedure and report any abnormal fluid levels to yourmaintenance persons.

Cold Check Procedure.The purpose of the cold check is to determine if thetransmission has enough fluid to be operated safely until a hot check can be made.

CAUTION: The fluid level rises as fluid temperature rises. DO NOT fillthe transmission above the “COLD CHECK” band if the transmissionfluid is below normal operating temperatures. During operation, anoverfull transmission can become overheated, leading to transmissiondamage.

Check the fluid level as follows:

1. Bring the vehicle to a complete stop on a level surface using the servicebrake.

2. Make sure the engine is at low idle rpm.

3. Put the transmission inP (Park),PB (Auto-Apply Parking Brake), orN (Neutral).

4. Apply any other parking brake, if present, and make sure it is properlyengaged.

5. Chock the wheels and take any other steps necessary to keep the vehiclefrom moving.

6. Run the engine at 1000–1500 rpm for at least one minute to purge air fromthe system. Apply the service brakes and shift toD (Drive), then toN (Neutral), and then shift toR (Reverse) to fill the hydraulic system.Finally, shift toP (Park) orPB (Auto-Apply Parking Brake), if available,or N (Neutral) and allow the engine to idle (500–800 rpm). Slowly releasethe service brakes.

7. With the engine running, remove the dipstick from the tube and wipe thedipstick clean.

8. Insert the dipstick into the tube and remove. Check the fluid level reading.Repeat the check procedure to verify the reading.

9. If the fluid level is within the “COLD CHECK” band (Figure entitledTypical Dipstick Markings), the transmission may be operated until thefluid is hot enough to perform a “HOT RUN” check. If the fluid level isnot within the “COLD CHECK” band, add or drain as necessary to bring itto the middle of the “COLD CHECK” band.

58

10. Perform a hot check at the first opportunity after the normal operatingsump temperature of 71°C–93°C (160°F–200°F) is reached.

Hot Check Procedure.

CAUTION: When performing the Hot Check procedure, the fluid mustbe hot to ensure an accurate check and help prevent transmissiondamage. The fluid level rises as temperature increases. During operation,an overfull transmission can become overheated, leading to transmissiondamage.

Operate the transmission inD (Drive) until normal operating temperature isreached:

• sump temperature 71°C–93°C (160°F–200°F)

• converter-out temperature 82°C–104°C (180°F–220°F)

• If a transmission temperature gauge is not present, check fluid level whenthe engine water temperature gauge has stabilized and the transmission hasbeen operated under load for at least one hour.

Check the fluid level as follows:

1. Bring the vehicle to a complete stop on a level surface using the servicebrake.

2. Make sure the engine is at low idle rpm.

3. Put the transmission inP (Park),PB (Auto-Apply Parking Brake), orN (Neutral).

V06713

HOT RUNBAND

COLD CHECKBAND

Figure 7. Typical Dipstick Markings

59

4. Apply any other parking brake, if present, and make sure it is properlyengaged.

5. Chock the wheels and take any other steps necessary to keep the vehiclefrom moving.

6. With the engine running, remove the dipstick from the tube and wipe thedipstick clean.

7. Insert the dipstick into the tube and remove. Check the fluid level reading.Repeat the check procedure to verify the reading.

NOTE: Safe operating level is within the “HOT RUN” band on thedipstick. See Figure entitled Typical Dipstick Markings. The width ofthe “HOT RUN” band represents approximately 1.0 liter (1.06 quart) offluid at normal operating sump temperature.

8. If the fluid level is not within the “HOT RUN” band, add or drain asnecessary to bring the fluid level to within the “HOT RUN” band.

Consistency of Readings.Always check the fluid level at least twice using theprocedure described above. Consistency (repeatable readings) is important tomaintaining proper fluid level. If inconsistent readings persist, check thetransmission vent assembly (breather) to be sure it is clean and unclogged. Ifreadings are still inconsistent, contact your nearest Allison distributor or dealer.

KEEPING FLUID CLEANPrevent foreign material from entering the transmission by using clean containers,fillers, etc. Lay the dipstick in a clean place while filling the transmission.

CAUTION: Containers or fillers that have been used for antifreezesolution or engine coolant must NEVER be used for transmission fluid.Antifreeze and coolant solutions contain ethylene glycol which, if putinto the transmission, can cause the clutch plates and some seals to fail.

FLUID RECOMMENDATIONSHydraulic fluids (oils) used in the transmission are important influences ontransmission performance, reliability, and durability. Any fluids meetingDEXRON®-III specifications are acceptable for use in the 1000 and 2000 ProductFamilies transmissions. TranSynd™ fluids fully meet the DEXRON®-IIIspecifications.

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To ensure the fluid is qualified for use in Allison transmissions, check for aDEXRON®-III fluid license or approval numbers on the container, or consult thelubricant manufacturer. Consult your Allison Transmission dealer or distributorbefore using other fluid types.

CAUTION: Disregarding minimum fluid temperature limits can resultin transmission malfunction or reduced transmission life.

When choosing the optimum viscosity grade of fluid to use, duty cycle, preheatcapabilities, and/or geographical location must be taken into consideration. Thetable below lists the minimum fluid temperatures at which the transmission maybe safely operated without preheating the fluid. Preheat with auxiliary heatingequipment or by running the equipment or vehicle with the transmission inP (Park) orPB (Auto-Apply Parking Brake), if available, orN (Neutral) for aminimum of 20 minutes before attempting range operation.

Transmission Fluid Operating Temperature Requirements

Ambient Temperature Below Which Preheat isRequired

Viscosity Grade Celsius FahrenheitDEXRON®-III –25° –13°

TranSynd™ –30° –22°(Ref. SIL 13-TR-90)

Some shift ranges and the torque converter clutch mode may not be reachedduring cold weather operation. As the transmission reaches normal operatingtemperature, all shift ranges and the torque converter clutch mode will begin tofunction.

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TRANSMISSION FLUID AND FILTER CHANGE INTERVALS

CAUTION: Transmission fluid and filter change frequency isdetermined by the severity of transmission service. To help avoidtransmission damage, more frequent changes can be necessary thanrecommended in the general guidelines when operating conditions createhigh levels of contamination or overheating.

Frequency.New vehicles delivered from the OEM with a mixture of TranSynd™and non TranSynd™ fluid must follow fluid/filter change recommendationsoutlined in Schedule 1 of the Transmission and Fluid Change table. If thecustomer fills the transmission with TranSynd™ or TES 295 equivalent, thechange recommendations of Schedule 1 must be followed.

Upon the next oil change, if the customer reinstalls TranSynd™ or TES 295equivalent, the fluid/filter change recommendations outlined in Schedule 2 may beused. The recommendations in Schedule 2 are based upon Allison fluid changeprocedures and the transmission containing 100% of TranSynd™ fluid.

For transmissions that contain a mixture of TranSynd™ and non-TranSynd™fluids, refer to Schedule 3.

NOTE: Flushing Machines are not recommended or recognized due tovariation and inconsistencies with ensuring removal of 100 percent ofthe used fluid.

Allison Transmission requires an initial filter change for the Spin-On ControlMain Filter during the first 8000 km (5000 miles) or 200 hours of service,whichever comes first. Following the initial filter change, change fluid/filters afterrecommended mileage, months, or hours have elapsed, whichever occurs first. SeeTransmission and Fluid Change table for recommendations. The transmissionsump filter is permanent and does not require replacement except at overhaul.

Severe Vocations include On/Off Highway, Refuse, City Transit, Shuttle, andMotorhomes. General Vocations includes all other vocations. Local conditions,severity of operation or duty cycle may require more or less frequent fluid changeintervals that differ from the published recommended fluid change intervals ofAllison Transmission. Transmission protection and fluid change intervals can beoptimized by the use of fluid analysis.

The following tables are given only as a general guide for fluid and filter changeintervals.

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

Vocation FluidFilters

Control Main Internal Lube/Auxiliary

General80 000 km

(50,000 miles)24 months

80 000 km(50,000 miles)

24 monthsOverhaul

80 000 km(50,000 miles)

24 months

Severe40 000 km


40 000 km(25,000 miles)

12 monthsOverhaul

40 000 km(25,000 miles)

12 months

Schedule 2. Recommended Fluid and Filter Change Intervals(TranSynd™ /TES 295 Fluid)



General160 000 km


80 000 km(50,000 miles)

24 monthsOverhaul

80 000 km(50,000 miles)

24 months

Severe80 000 km


80 000 km(50,000 miles)

24 monthsOverhaul

80 000 km(50,000 miles)

24 months

Schedule 3. Modified Fluid and Filter Change Intervals With a Mixture *of TranSynd™ and Non-TranSynd™ Fluids



General80 000 km


80 000 km(50,000 miles)

24 monthsOverhaul

80 000 km(50,000 miles)

24 months

Severe40 000 km


40 000 km(25,000 miles)

12 monthsOverhaul

40 000 km(25,000 miles)

12 months* Mixture is defined as the quantity of oil remaining in the transmission after a standard fluidchange combined with the quantity of TranSynd™ that is required to fill the transmission to theproper level. A mixture of TranSynd™ or TES 295 equivalent vs. non-TranSynd™ other than asdefined in this paragraph does not meet the requirements that permit the eligibility for therecommendations given in Schedule 3.

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Abnormal Conditions. Transmissions used in high cycle rate applications shoulduse fluid analysis to be certain that a proper fluid change interval is established.Transmission fluid must be changed whenever there is evidence of dirt or a hightemperature condition. A high temperature condition is indicated by thetransmission fluid being discolored or having a strong odor, or by fluid analysis.Local conditions, severity of operation, or duty cycle may require more or lessfrequent fluid or filter change intervals.

Fluid Analysis. Transmission protection and fluid change intervals can beoptimized by monitoring fluid oxidation according to the tests and limits shown inthe following table. Fluid oxidation can be monitored through a fluid analysis firmand/or by using an oil analysis kit.

• Fluid analysis firms—Consult your local telephone directory for fluidanalysis firms. To ensure consistent and accurate fluid analysis, use onlyone fluid analysis firm. Refer to the Technician’s Guide for AutomaticTransmission Fluid, GN2055EN, for additional information.

• Oil analysis kits, part number 29537805, are available through your normalAllison Transmission parts source.

Refer to the Technician’s Guide for Automatic Transmission Fluid, GN2055EN,for additional information.

Fluid Oxidation Measurement Limits

Test LimitViscosity ±25% change from new fluidTotal Acid Number +3.0* change from new fluid* mg of KOH required to neutralize a gram of fluid.

TRANSMISSION FLUID CONTAMINATION

Fluid Examination. At each fluid change, examine the drained fluid for evidenceof dirt or water. A normal amount of condensation will appear in the fluid duringoperation.

Water. Obvious water contamination of the transmission fluid or transmissionfluid in the cooler water (in heat exchanger) indicates a leak between the waterand fluid areas of the cooler. Inspect and pressure test the cooler to confirm theleak. Replace leaking coolers.

NOTE: Cooler water can also be contaminated by engine oil; be sure tolocate the correct source of cooler water contamination.

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Engine Coolant.

CAUTION: If the transmission fluid is contained by water, 0.2 percentby volume, or any trace of ethylene glycol, disassemble the transmissionand replace the following:

• Seals• Gaskets• Clutch plates• Bearings• Torque converters that cannot be disassembled• Components that have rusted• Solenoids that do not meet resistance specifications

Remove all traces of ethylene glycol and varnish deposits. Failure tofollow this procedure decreases transmission reliability and durability.

Metal. Metal particles in the fluid (except for the minute particles normallytrapped in the oil filter) indicate internal transmission damage. If these particlesare found in the sump, the transmission must be disassembled and closelyinspected to find their source. Metal contamination requires complete transmissiondisassembly. Clean all internal and external hydraulic circuits, cooler, and all otherareas where the particles could lodge.

COOLER FLUSHING PROCEDUREMetal contamination requires complete transmission disassembly and cleaning.Clean all internal and external hydraulic circuits, transmission cooler, and all areaswhere metal and other particles could lodge. Special tool J 46550 TransmissionCooler Kwik-Flush Cart is now an essential tool for all overhaul and maintenanceservice outlets, J 46550 or an approved cooler flushing device that meets Allisoncooler flushing requirements and procedures.

1. Flush contaminated fluid from the cooler by flowing transmission fluidthrough the cooler in the reverse direction of normal flow. Use a flushingpump that pumps fluid in a pulsating flow at a minimum mean rate of0.5 liters/sec (8.0 gpm) and 275–345 kPa (40–50 psi). The J 46550Transmission Cooler Kwik-Flush Cart meets these requirements.

2. After flushing the contaminated fluid, use the flushing pump to circulateclean transmission fluid through the cooler in a closed loop back to a10–micron filter. Circulate fluid in the closed loop for a minimum of fiveminutes.

CAUTION: After flushing the cooler, be sure to check the externalcooler circuit restriction. If circuit pressure drop is above specification,the cooler has excessive trapped particles and must be replaced.

65

NOTE: When equipment to flush the oil cooler is not available, install afilter in the cooler line between the oil cooler and the transmission“from cooler” port. The cooler circuit pressure drop specifications muststill be met (see AS64–071 or AS64–072 in the Allison Sales Tech Databook). Frequent initial changes of this filter element may be required asdebris is flushed out of the oil cooler circuit. Closely monitoring changein cooler circuit pressure drop will indicate when a filter change isneeded.

TRANSMISSION FLUID AND FILTER CHANGEPROCEDURE

Drain Fluid.

1. Drain the fluid when the transmission is at normal operating sumptemperature of 71–93°C (160–200°F). Hot fluid flows quicker and drainsmore completely.

2. Remove the drain plug from the oil pan and allow the fluid to drain into asuitable container.

3. Examine the fluid as described in the TRANSMISSION FLUIDCONTAMINATION paragraph in this Section.

Replace Control-Main Filter (refer to Figure 8).

1. Using a standard strap-type filter wrench or the J 45023, remove thecontrol-main filter by rotating it in the counterclockwise direction.

2. Remove the magnet from the filter attachment tube or from the top of thefilter element.

3. Clean any metal debris from the magnet. Report any metal pieces largerthan dust to your maintenance personnel.

4. Reinstall the magnet onto the filter attachment tube.

5. Lubricate the gasket on the control-main filter with transmission fluid.

6. Install, by hand, the control-main filter until the gasket on the control-mainfilter touches the converter housing or cooler manifold.

CAUTION: Turning the control-main filter more than ONE FULLTURN after gasket contact will damage the filter.

7. Using the J 45023 or by hand, turn the filter ONE FULL TURN ONLYafter gasket contact.

8. Reinstall the drain plug and sealing washer. Tighten the drain plug to30–40 N·m (22–30 lb ft).

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Refill Transmission. The amount of refill fluid is less than the amount used forthe initial fill. Fluid remains in the external circuits and transmission cavities afterdraining the transmission.

After refill, check the fluid level using the TRANSMISSION FLUID CHECKparagraph of this Manual.

MAGNET

FILTER

J 45023

V06712.01.00

Figure 8. Replacing the Control-Main Filter

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Transmission Fluid Capacity

SumpInitial Fill * Refill*

Liters Quarts Liters QuartsStandard 14 14.8 10 10.6Shallow 12 12.7 7 7.4

* Approximate quantities, do not include external lines and cooler hose.

VENT ASSEMBLY

Location and Purpose.The vent assembly is located at the top left-rear of thetransmission main housing. The vent assembly prevents air pressure buildupwithin the transmission and its passage must be kept clean and open.

CAUTION: Do not spray steam, water, or cleaning solution directly atthe vent assembly (breather). Spraying steam, water, or cleaning solutionat the vent assembly can force the water or cleaning solution into thetransmission and contaminate the transmission fluid. Seal all openingsand the vent assembly (breather) before spraying steam, water, orcleaning solutions on the transmission.

Maintenance.The amount of dust and dirt encountered will determine thefrequency of vent assembly cleaning. Use care when cleaning the transmission.

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DIAGNOSTIC CODES AND TOOLSDiagnostic features are provided with the transmission control system to assist inthe troubleshooting of malfunctions. These features include a red or amberCHECK TRANS light or some type of Malfunction Indicator Light (MIL), aPC-based diagnostic program, and an optional hand-held scan tool. TheCHECKTRANS and MIL lights are located on the dash panel. For vehicles which arecompliant to industry On Board Diagnostics II (OBD II) requirements, an MILLight will be present. For vehicles which are not compliant to industry OBD IIrequirements, aCHECK TRANS light will be present. The PC-based diagnosticprogram can troubleshoot all transmissions. The hand-held scan tool cantroubleshoot only some transmissions.

Illumination of theCHECK TRANS light at any time after start-up indicates thatthe TCM has registered a diagnostic trouble code (DTC). Diagnostic codes areused to identify and clarify the nature of the malfunction. Diagnostic codes areread and cleared through the PC-based diagnostic program or the hand-held scantool.

Illumination of the MIL Light at any time after start-up may indicate a problemwith the engine or transmission.

For further information, consult an authorized Allison Transmission distributor orservice dealer or the websitewww.allisontransmission.com.Reference the Salesand Service Directory (SA2229) for the current listing of Allison Transmissionauthorized distributor and service dealers.

DIAGNOSTICS

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OWNER ASSISTANCEThe satisfaction and goodwill of the owners of Allison transmissions are ofprimary concern to Allison Transmission, its distributors, and their dealers.

As an owner of an Allison transmission, you have service locations throughout theworld 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, orservice of your transmission will be handled by the distributor or dealer in yourarea (check the telephone directory for the Allison Transmission service outletnearest you).

Refer to Worldwide Sales and Service Directory (SA2229EN) for the currentlisting of Allison Transmission authorized distributor and service dealers. Thisdirectory is available from SGI, Inc.

We recognize, however, that despite the best intentions of everyone concerned,misunderstandings may occur. To further assure your complete satisfaction, wehave developed the following three-step procedure to be followed in the event aproblem has not been handled satisfactorily.

Step One—Discuss the problem with a member of management from thedistributorship or dealership. Frequently, complaints are the result of abreakdown in communication and can quickly be resolved by a member ofmanagement. If you have already discussed the problem with the Sales or ServiceManager, contact the General Manager. All Allison Transmission dealers areassociated with an Allison Transmission distributor. If the problem originates witha dealer, explain the matter to a management member of the distributorship withwhom the dealer has his service agreement. The dealer will provide his AllisonTransmission distributor’s name, address, and telephone number on request.

Step Two—When it appears the problem cannot be resolved readily at thedistributor level without additional assistance,contact the Allison Transmission

CUSTOMER SERVICE

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Regional Office responsible for the local distributor.You will be assisted by amember of the Regional Service Manager’s staff, depending on the nature of yourproblem.

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 (ifequipped with electronic controls, also provide the TCM 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 followingaddress or calling the phone number below:Allison TransmissionManager, Warranty AdministrationPO Box 894, Mail Code 462-470-PF9Indianapolis, IN 46206-0894800–252–5283

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

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

Your purchase of an Allison Transmission product is greatly appreciated, and it isour sincere desire to assure complete satisfaction.

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SERVICE LITERATUREAdditional service literature is available. This service literature provides fullyillustrated instructions for the operation, maintenance, service, overhaul, and partssupport of your transmission. To ensure that you get maximum performance andservice life from your unit, you may order publications from:

SGI, Inc.Attn: Allison Literature Fulfillment Desk8350 Allison AvenueIndianapolis, IN 46268TOLL FREE: 888–666–5799INTERNATIONAL: 317–471–4995www.allisontransmission.com

1000 and 2000 Product Families Service Literature

Automatic Transmission Fluid Technician’s Guide GN2055EN*Mechanic’s Tips MT3190EN*Operator’s Manual OM3063EN*Parts Catalog PC3062ENParts Catalog CD-ROM CD3062ENPrinciples of Operation PO3065ENService Manual SM3191ENTransmission In-Chassis Maintenance JA3664ENTroubleshooting Manual TS3192ENWorldwide Sales & Service Directory SA2229EN*Also available on the internet atwww.allisontransmission.com

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ALLISON TRANSMISSION DISTRIBUTORS

EASTERN REGION

Atlantic Detroit Diesel-Allison, LLC180 Route 17 SouthLodi, NJ 07644201-489-5800

Penn Detroit Diesel-Allison, Inc.8330 State RoadPhiladelphia, PA 19136-2986215-335-0500

Covington Detroit Diesel-Allison8015 Piedmont Triad ParkwayGreensboro, NC 27409336-292-9240

Western Branch Diesel, Inc.3504 Shipwright StreetPortsmouth, VA 23703757-673-7000

Johnson & Towers, Inc.2021 Briggs RoadMount Laurel, NJ 08054856-234-6990

W.W. Williams S.E., Inc.2849 Moreland Avenue, S.EAtlanta, GA 30315-0037404-366-1070

New England Detroit Diesel-Allison, Inc.90 Bay State RoadWakefield, MA 01880-1095781-246-1810

CENTRAL REGION

Central Detroit Diesel-Allison, Inc.9200 Liberty DriveLiberty, MO 64068816-781-8070

Inland Detroit Diesel-Allison, Inc.210 Alexandra WayCarol Stream, IL 60188630-871-1111

Clarke Detroit Diesel-Allison, Inc.3133 East Kemper RoadCincinnati, OH 45241513-771-2200

Inland Diesel, Inc.13015 West Custer AvenueButler, WI 53007-0916262-781-7100

Detroit Diesel-Allison Canada EastDiv. of Integrated Power Systems Corp.2997 Rue WattSte. Foy, Quebec G1X 3W1418-651-5371

Interstate Detroit Diesel2501 American Boulevard, EastMinneapolis, MN 55425952-854-5511

Harper Detroit Diesel Ltd.10 Diesel DriveToronto, Ontario M8W 2T8416-259-3281

W.W. Williams M.W., Inc.1176 Industrial ParkwayNorth Brunswick, OH 44212-2342330-225-7751

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SOUTHERN REGION

Caribe Detroit Diesel-AllisonDivision of GT CorporationCeramic Ind. ParkCampo Rico Ave., Block CCarolina, Puerto Rico 00982787-750-5000

Stewart & Stevenson Power, Inc.5840 Dahlia StreetCommerce City, CO 80022303-287-7441

Detroit Diesel-Allison de Mexico S.A.de C.V.Av. Santa Rosa No. 58Col. Ampliacion NorteTlalnepantla C.P. 54160, Mexico525-5-5333-1800

Stewart & Stevenson Services, Inc.2707 North Loop WestHouston, TX 77008713-868-7700

Florida Detroit Diesel-Allison, Inc.2277 N.W. 14th StreetMiami, FL 33125-0068904-737-7330

United Engines, LLC5555 West Reno StreetOklahoma City, OK 73127405-947-3321

WESTERN REGION

Detroit Diesel-Allison BritishColumbia Ltd.9300 - 192nd StreetSurrey, British Columbia V4N 3R8604-888-1211

Stewart & Stevenson1755 Adams AvenueSan Leandro, CA 94577-1001510-635-8991

Midwest Detroit Diesel-Allison Ltd.1460 Waverly StreetWinnipeg, Manitoba R3T OP6204-452-8244

Valley Power Systems, Inc.425 South Hacienda BoulevardCity of Industry, CA 91745-1123626-333-1243

Pacific Detroit Diesel-Allison Company7215 South 228th StreetKent, WA 98032253-854-0505

Waterous Detroit Diesel-Allison, Inc.10025 - 51st AvenueEdmonton, Alberta T6E OA8780-437-3550

Smith Detroit Diesel-Allison, Inc.3065 West California AvenueSalt Lake City, UT 84104801-415-5000

W.W. Williams S.W., Inc.2602 S. 19th AvenuePhoenix, AZ 85009602-257-0561

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ALLISON TRANSMISSION REGIONAL OFFICES

EASTERN REGION19 Oaklynn DrivePO Box 400Columbus, NJ 08022-0400609-298-2541

SOUTHERN REGIONAv. Ejercito Nacional No. 843Colonia GranadaMexico, D.F. C.P. 11520936-321-4248

CENTRAL REGIONPO Box 894, Mail Code 462-470-PF06Indianapolis, IN 46206-0894317-242-2327

WESTERN REGIONSuite 351039465 Paseo Padre ParkwayFremont, CA 94538510-226-8037

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OM3063EN 200306 Printed in USA 200408www.allisontransmission.com

operator's manual 1000 and 2000 product...

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