Allison Transmission AT 500 Series Manual
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Allison Transmission AT 500 Series Manual

Allison Transmission AT 500 Series Manual

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Mechanic's Tips
AT 500 and AT 1500
Series Transmissions
MT1321EN
MT4108EN

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Summary of Contents for Allison Transmission AT 500 Series

  • Page 1 Mechanic’s Tips AT 500 and AT 1500 Series Transmissions MT1321EN MT4108EN...
  • Page 2 AT 542, AT 542N, AT 542R, AT 542NR AT 545, AT 545N, AT 545R, AT 545NR, AT 542NFE AT 1542, AT 1542P, AT 1542NP AT 1545, AT 1545P, AT 1545NP June 1996 Revision 1, 1999 April Copyright © 2007 Allison Transmission, Inc. Printed in U.S.A.
  • Page 3 IT IS YOUR RESPONSIBILITY to be completely familiar with the warnings and cautions described in this handbook. It is, however, important to understand that these warnings and cautions are not exhaustive. Allison Transmission could not possibly know, evaluate, and advise the service trade of all conceivable ways in which service might be done or of the possible hazardous consequences of each way.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS Paragraph Description Page Section I PREVENTIVE MAINTENANCE 1–1 Periodic Inspection and Care ......1 1–2 Importance of Proper Fluid Level .

  • Page 5: Description Page

    Paragraph Description Page Section IV PREPARING VEHICLE FOR TRANSMISSION INSTALLATION 4–1 Checking Flexplate, Engine Features....25 4–2 Checking Chassis, Driveline ......27 4–3 Checking Cooler, Tubes, Hoses, Fittings.
  • Page 6 PREFACE This handbook is a ready reference for the mechanic removing, installing, or maintaining AT Series Automatic Transmissions. All features of both the vehicle and transmission that become involved in the installation procedures are discussed. The information presented will help the mechanic to remove, install, and maintain the transmission in a manner that assures satisfactory operation and long service life.
  • Page 7 Model AT 542 Transmission — Left-Front View Model AT 545 Transmission — Right-Front View Model AT 545R Transmission — Right-Front View...

  • Page 8: Sectioni

    PREVENTIVE ECTION MAINTENANCE 1–1. PERIODIC INSPECTION AND CARE Clean and inspect the exterior of the transmission at regular intervals. The severity of service and operating conditions will determine the frequency of such inspections. Inspect the transmission for the following items: •...
  • Page 9 NOTE: The ADD and FULL dimensions on earlier dipsticks coincide with the HOT RUN band dimensions on later dipsticks. TOP OF OIL PAN 0.50 in. (12.7 mm) 1.00 in. (25.4 mm) 1.50 in. (38.1 mm) 1.80 in. (45.7 mm) NOTE: This illustration is not a template, placement of markings will vary according to the installation angle of the dipstick tube.

  • Page 10: Fluid Check Procedure

    1–4. FLUID CHECK PROCEDURE WARNING: When checking the fluid level, be sure the transmission is in N (Neutral) or P (Park), parking brake and/or emergency brakes are set and properly engaged, and the wheels are chocked. Unexpected and possible sudden vehicle movement may occur if these precautions are not taken.

  • Page 11: Keeping Fluid Clean

    until the fluid is hot enough to perform a HOT RUN check. If the fluid level is not within the COLD RUN band, add or drain fluid as necessary to bring the level to the middle of the COLD RUN band. •...

  • Page 12: Fluid And Filter Change Intervals

    fluid is qualified for use in Allison transmissions, check for a DEXRON C-4 fluid license, or approval numbers on the container, or consult the lubricant manufacturer. Consult your Allison Transmission dealer or distributor before using other fluid types; fluid types such as Type F and universal farm fluids may or may not be properly qualified for use in your...

  • Page 13: Fluid And Filter Change Procedure

    Table 1–2. Fluid and Filter Change Intervals External Auxiliary Fluid Change Internal Sump Transmission Filters** Paper Filter: Paper Filter: at After first 5000 25,000 miles each fluid change miles (8 000 km) (40 000 km) interval and at 25,000 miles On-Highway, or 12 months* Brass Filter:...
  • Page 14 • Remove the pan and filter. Discard the pan gasket, filter, and filter tube sealring. Clean the pan. • Remove, clean, and reinstall the governor feed line screen in the control valve body. • For models with the shallow pan (3.8 inch, 97 mm), insert a new sealring into the filter tube.

  • Page 15: Fluid Contamination

    Table 1–3. Transmission Fluid Refill Capacities Pan Type Quantity Shallow pan — 3.8 inches (97 mm) 9 U.S. qt. (8.5 liters)* Deep pan — 5.3 inches (135 mm) 16 U.S. qt. (15 liters)* * The amount of transmission fluid shown in the following chart does not include the amount required to fill the external circuits.

  • Page 16: Auxiliary Filter

    Fluid Analysis Transmission protection and fluid change intervals can be optimized by monitoring oxidation according to the tests and limits shown in Table 1–4. Consult your local telephone directory for fluid analysis firms. Use one fluid analysis firm as results from various firms cannot be accurately compared.

  • Page 17: Breather

    The following auxiliary filters are recommended: Table 1–5. Auxiliary Filter Recommendations Filter Assembly Filter Element Allison 29510923* Allison 29510922* AC PM 13-16 PF 897 AC PM 16-1 PF141 FX 11583 HF6520 Fram HP 1-1 HP 1 or AC HD 222 Purolator OF-15C-1 OF-2C-1 Purolator 20-10...
  • Page 18 Transmission Stall Test Procedure The engine stall point (rpm) under load is compared to the engine manufacturer’s specified rpm for the stall test. WARNING: When conducting a stall test, the vehicle must be positively prevented from moving. Apply the parking brake and service brake, and block the vehicle securely.
  • Page 19 Neutral Cool-Down Check Procedure The neutral cool-down check determines if the transmission fluid cools following an engine load condition. Perform this check immediately after the engine speed has been recorded in the stall test. • Record the converter-out fluid temperature. •...

  • Page 20: Removing Transmission

    REMOVING ECTION TRANSMISSION 2–1. DRAINING TRANSMISSION • Remove the drain plug from the pan. Disconnect the transmission fill tube from the pan only if required. Remove the fill tube completely if it interferes with transmission removal. • Examine the drained fluid for evidence of contamination (refer to Paragraph 1–9).

  • Page 21: Uncoupling Engine From Driveline

    2–3. UNCOUPLING ENGINE FROM DRIVELINE • Chock the wheels to prevent the vehicle from rolling. • Disconnect the vehicle driveline from the transmission output flange or yoke. Position the drive shaft to avoid interference with transmission removal. • Figure 2–1 shows two typical methods of coupling the engine and transmission.

  • Page 22: Removing Mounting Bolts

    (if used). • Attach a retaining strap (Figure 2–2) across the converter drive cover and transmission housing at the earliest opportunity. 2–6. REPAIR INSTRUCTIONS • Refer to the applicable Allison Transmission Service Manual to repair the transmission. Refer to Paragraph 7–2.
  • Page 23 TORQUE CONVERTER RETAINING STRAP GOVERNOR COVER TORQUE CONVERTER MODULATOR SELECTOR RETAINER OIL PAN LEVER H00387.01 Figure 2–2. Location of Torque Converter Retaining Strap...

  • Page 24: Preparing Transmission For Installation

    — AT 543 models: 1.600–1.721 inches (40.64–43.71 mm) — AT 1500 Series models: 2.715–2.875 inches (68.96–73.03 mm) • A measurement outside these dimensions indicates the torque converter is not installed properly. (Refer to the applicable Allison Transmission Service Manual. Refer to Paragraph 7–2.)

  • Page 25: Installing Parking Brake And Output Flange

    • Check the output flange rear oil seal to ensure that it has not been damaged and is free of defects. For replacement instructions, refer to the applicable Allison Transmission Service Manual. Refer to Paragraph 7–2. • Lubricate the oil seal with petrolatum or transmission fluid.

  • Page 26: Installing Shift Selector Lever

    • The output flange is retained by a ⁄ -20 x 1 ⁄ inch bolt and a 1 ⁄ inch washer. Replace the bolt and washer each time they are removed. Tighten the bolt to 102–121 lb ft (138–164 N·m). NOTE: Bolt P/N 29510838 with improved torque retention should be used.

  • Page 27: Installing Power Takeoff (Pto)

    Figure 3–2. Tightening Selector Lever Nut 3–5. INSTALLING POWER TAKEOFF (PTO) CAUTION: Cork or other soft gaskets must never be used to mount the PTO. Use only shims or gaskets recommended by the PTO manufacturer. Space limitations will determine whether the PTO should be installed before or after the transmission is installed.

  • Page 28: Installing Shift Modulation Control

    TRANSMISSION BASE PLATE MAIN CASE GAUGE PIN MEASUREMENT PTO PAD HOLD DOWN BOLT PTO DRIVE J 34814 GEAR V02394 Measurement Correction 0.011–0.045 in. (0.27–1.16 mm) one–0.030 in. Gasket (one 0.76 mm Gasket) 0.047–0.070 in. (1.19–1.78 mm) two–0.030 in. Gaskets (two 0.76 mm Gaskets) Figure 3–3.

  • Page 29: Installing Fill Tube And Drain Plug

    PTO DRIVE GEAR SNAPRING 3RD RANGE CLUTCH BACKPLATE H00388.01 Figure 3–4. View at PTO Opening 3–7. INSTALLING FILL TUBE AND DRAIN PLUG The fill tube may be installed before the transmission is put into the vehicle, unless its presence will interfere with transmission installation. •...

  • Page 30: Installing Neutral Start And Reverse Signal Switches

    3–8. INSTALLING NEUTRAL START AND REVERSE SIGNAL SWITCHES • Connect any wiring required for sensors, signals, switches, or other electrical components. • Install the Neutral Start Switch (if so equipped) into the opening directly above the selector shaft in the left side of the transmission housing. The switch must include an aluminum washer (gasket) approximately 0.090 inch (2.29 mm) thick.

  • Page 31: Checking Breather

    3–10. CHECKING BREATHER Ensure the breather is clean and free of obstructions. Also, the breather cap must be loose and free to rattle. Figure 3–5 shows the two breather configurations. • The earlier breathers should be equipped with a neoprene shroud (P/N 6883025).

  • Page 32: Preparing Vehicle For Transmission Installation

    These measurements are summarized in Table 4–1. Figure 4–1 illustrates the tooling required for these measurements. Reference SIL 60-TR-81 (latest revision). Figure 4–1. Tooling Used to Determine the Adaptation Measurements of an AT 500 Series Transmission...
  • Page 33 Table 4–1. Measurements Component or Required Inspections Limits Subassembly Bore Diameter 16.125–16.130 in. (409.58–409.70 mm) Flywheel Housing Bore Eccentricity* 0.020 in. (0.51 mm) T.I.R. Face Squareness* 0.020 in. (0.51 mm) T.I.R. Converter Pilot 1.703–1.705 in. Diameter (43.26–43.31 mm) Crankshaft Hub and/or Adapter Face Squareness 0.0005 in.

  • Page 34: Checking Chassis, Driveline

    4–2. CHECKING CHASSIS, DRIVELINE Inspect the chassis and driveline and correct any faulty conditions: • Broken or worn transmission mounts. • Missing, cracked, or swollen isolators (rubber mounts). • Improper or damaged bolts or other hardware. • Permanent deformation of springs in rear support. •...

  • Page 35: Checking Controls

    NOTE: For AT 500R transmissions, the minimum size for primary cooler hose is No. 16 with a minimum ID of 0.875 inch (22.4 mm) and for auxiliary cooler hose is No. 8 with a minimum ID of 0.50 inch (12.7 mm). •...

  • Page 36: Installing Transmission Into Vehicle

    INSTALLING ECTION TRANSMISSION INTO VEHICLE 5–1. HANDLING CAUTION: The transmission must be handled very carefully after the torque converter retaining strap is removed to avoid separating the torque converter from the transmission. Keep the transmission level or the rear slightly lower than the front at all times. •...

  • Page 37: Installing Transmission Mounting Components

    FLYWHEEL HOUSING PILOT PLATE Make from M -10 x 38 mm (1.5 in.) Bolt TAPER Screwdriver slot to aid removal V03008 Figure 5–1. Pilot Tool for Installation (AT 500, AT 1500) • Tighten the flexplate nuts (AT 543) to 34–40 lb ft (46–54 N·m). •...

  • Page 38: Coupling To Driveline

    5–4. COUPLING TO DRIVELINE • Couple the driveline companion flange or universal joint yoke to the transmission output flange or yoke. • Use the bolts, nuts, and torque specified by the vehicle manufacturer. 5–5. INSTALLING VACUUM OR AIR MODULATOR CONTROL NOTE: There are 12V and 24V electric modulators available as of June 1994.

  • Page 39: Connecting Cooler, Vacuum Lines, Air Lines

    5–6. CONNECTING COOLER, VACUUM LINES, AIR LINES • Connect the lines from the transmission to the cooler forming a transmission fluid-to-water counterflow in the cooler. Vertical-mounted coolers require the transmission to-cooler line to be connected to the bottom port in the cooler to avoid air-locking the cooler.

  • Page 40: Connecting Shift Selector Control

    5–8. CONNECTING SHIFT SELECTOR CONTROL • Place the operator’s shift selector control at the N (Neutral) position. Place the selector lever (hidden inside the transmission pan) in the N (Neutral) position by one of the following two methods (Figure 5–4): •...

  • Page 41: Installing, Adjusting Mechanical Modulator Control

    5–9. INSTALLING, ADJUSTING MECHANICAL MODULATOR CONTROL NOTE: There are 12V and 24V electric modulators available as of June 1994. See SIL 27-TR-94. • Connect the engine (throttle) end of the modulator cable housing to its mounting. • Open the engine throttle fully and check whether the throttle linkage will push or pull the cable core when the throttle linkage is moving toward full throttle position.

  • Page 42: Connecting Power Takeoff Controls

    • Install the O-ring seal onto the modulator control. Coat the O-ring with oil- soluble grease. • Install the modulator control into the transmission. Install the control housing, and secure it with the retainer and the ⁄ -18 x ⁄ inch bolt provided.

  • Page 43: Filling The Transmission

    • Install the speedometer drive cable onto the driven gear assembly. Tighten the cable nut to 50–55 lb in. (5.6–6.2 N·m). Avoid sharp bends in the cable. The torque required to drive the cable and all associated equipment should not exceed 25 oz-in.

  • Page 44: Checks And Adjustment

    CHECKS AND ECTION ADJUSTMENTS 6–1. INSTALLATION CHECKLIST • PROPER TORQUE Drive cover bolts (AT 540, AT 542, AT 542N, AT 545, AT 545N, and AT 1500 Series) — 42–50 lb ft (57–68 N·m) Flexplate nuts (AT 543) — 34–40 lb ft (46–54 N·m) Transmission-to-engine bolts* Transmission-to-frame mounting bolts —...
  • Page 45 • PROPER TORQUE (cont’d) Neutral start switch to transmission housing — 50–60 lb ft (68–81 N·m) Reverse signal switch to transmission housing — 4–5 lb ft (5–7 N·m) Modulator retaining bolt — 10–16 lb ft (14–22 N·m) Retarder low speed cutoff switch in transmission housing — 4–5 lb ft (5–7 N·m) Retarder temperature sensor fitting in retarder valve body —...
  • Page 46 • DRIVELINE Check for proper indexing of universal joints Check for proper drive shaft angles Check driveline backlash Lubricate universals and slip-joints • HYDRAULIC SYSTEM Recommended fluid (refer to Paragraph 1–6) Sufficient fluid in transmission (refer to Paragraph 1–4) Dipstick properly marked Fill cap tight Fill tube tight at pan Breather clean, free of restriction...

  • Page 47: Road Test And Vehicle Operation Checklist

    • MOUNTING (cont’d) Tail support preload correct Engine/transmission properly aligned Linkages and hoses do not restrain engine “roll” on acceleration 6–2. ROAD TEST AND VEHICLE OPERATION CHECKLIST • NEUTRAL START Check the position of the operator’s selector lever in each drive range and N (Neutral).
  • Page 48 • SHIFT SEQUENCE Drive the vehicle and check the wide-open throttle upshift points. If adjustment of the shift points is required, refer to the applicable AT Service Manual. The shifts should occur at the following speeds: — 1–2 upshift occurs within 400 rpm of full-load governed speed —...

  • Page 49: Customer Service

    The satisfaction and good will of the owners of Allison transmissions are of primary concern to Allison Transmission Division (ATD), its distributors, and their dealers. As an owner of an Allison transmission, you have service locations throughout the world that are eager to meet your parts and service needs with: •...
  • Page 50 Therefore, it is suggested the above steps be followed in sequence when experiencing a problem. Your purchase of an Allison Transmission product is greatly appreciated, and it is our sincere desire to assure complete satisfaction.

  • Page 51: Service Literature

    To ensure that you get maximum performance and service life from your unit, see your dealer or distributor for the following publications. Check the telephone directory for the Allison Transmission service outlet nearest you. Table 7–1. Service Literature...
  • Page 52 MT1321EN 199606 www.allisontransmission.com Printed in USA 199804...

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At 1500 seriesAt 540At 543At 542At 542nAt 542r ... Show all

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