Allison Transmission Sa2457B 1999 Service Manual-21516A320003.pdf
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B 500 PARTS CATALOG

INTRODUCTION

	ELECTRONIC CONTROL UNIT AND DIAGNOSTIC DATA READER

	TRADEMARK USAGE

	IMPORTANT SAFETY NOTICE

	WARNINGS, CAUTIONS, AND NOTES

	LIST OF WARNINGS

TABLE OF CONTENTS

LIST OF FOLDOUT ILLUSTRATIONS

1 - GENERAL INFORMATION

	1-1. SCOPE OF MANUAL

	1-2. SUPPLEMENTARY

	1-3. ORDERING PARTS

	Figure 1-1. Model HD 4060P14560P

	Figure 1-2. Model HD 4060P

	Figure 1-3. Model HD 4060PR

	Figure 1-4. Model HD 4060PR14560PR

	1-4. GENERAL DESCRIPTION

	1-5. MAJOR COMPONENTS

	1-6. MODEL DESIGNATION CODE

	1-7. EXPLODED VIEWS

	1-8. DIAGNOSIS

	1-9. PRESERVATIONAND STORAGE

	1-10. RESTORING TRANSMISSION TO SERVICE

	1-11. ELECTROMAGNETIC

	1-12. OPERATING INSTRUCTIONS

	1-13. SPECIFICATIONS AND DATA

		Table 1-1. Specifications and Data Chart*

2 - PREVENTIVE MAINTENANCE

	2-1. SCOPE

	2-2. PERIODIC INSPECTION AND CARE

	2-3. IMPORTANCE OF PROPER FLUID LEVEL

	2-4. ELECTRONIC FLUID LEVEL CHECK

	2-5. MANUAL FLUID LEVEL CHECK PROCEDURE

	2-6. COLD CHECK

	2-7. HOT CHECK

		Figure 2-1. Fluid Dipstick Markings

	2-8. KEEPING FLUID CLEAN

	2-9. FLUID RECOMMENDATIONS

		Table 2-1. Transmission Fluid Operating Temperature Requirements

	2-10. FLUID AND FILTER CHANGE INTERVALS

	2-11. FLUID CONTAMINATION

	2-12. FLUID AND FILTER CHANGE PROCEDURE

		Figure 2-2. Filter Change

		Table 2-2. Transmission Fluid Capacity

	2-13. BREATHER

	2-14. TRANSMISSION STALL TEST AND NEUTRAL COOL DOWN CHECK

	2-15. CHECKING CLUTCH PRESSURES

		Figure 2-3. Clutch Pressure Check Points

		Table 2-3. Main Pressure and Clutch Pressure Specifications

	2-16. FLUID LEAK DIAGNOSIS

	2-17. OUTPUT FLANGE

		Figure 2-4. Output Flange and Oil Seal

	2-18. ON-VEHICLE MAINTENANCE

3 - GENERAL OVERHAUL INFORMATION

	3-1. SCOPE

	3-2. TOOLS AND EQUIPMENT

		Figure 3-1. Work Table

		Figure 3-2. Special Tools

	3-3. REPLACEMENT PARTS

	3-4. CAREFUL HANDLING

	3-5. CLEANING AND INSPECTION

		Table 3-1. HD 4000

		Figure 3-3. Method of Measuring Clutch Plate Cone

	3-6. ASSEMBLY PROCEDURES

	3-7. REMOVING TRANSMISSION FROM VEHICLE

		Figure 3-4. Disconnection Locations

	3-8. WEAR LIMITS

	3-9. SPRING SPECIFICATIONS

	3-10. TORQUE SPECIFICATIONS

4 - TRANSMISSION DISASSEMBLY

	4-1. SCOPE

	4-2. DISASSEMBLY OF TRANSMISSION

		Figure 4-1. PTO Removal

		Figure 4-2. Removal of Externally Mounted Parts

		Figure 4-3. Speed Sensors

		Figure 4-4. Control Module Removal

		Figure 4-5. Torque Converter Module Removal

		Figure 4-6. Converter Housing Module Removal

		Figure 4-7. P2 Module and C5 Clutch Plates

		Figure 4-8. Rear Cover Module Removal

		Figure 4-13. Rotating Clutch Module Removal

		Figure 4-14. C3

5 - MODULE REBUILD

	5-1. SCOPE

	5-2. GENERAL INFORMATION FOR MODULE REBUILD

	5-3. TORQUE CONVERTER MODULE

		Figure 5-1. Stator Roller

		Figure 5-2. Torque Converter Selective Shim Procedure

		Table 5-1. Torque Converter Selective Shims

	5-4. TORQUE CONVERTER HOUSING MODULE (Models without PTO)

	5-5. TORQUE CONVERTER HOUSING MODULE (Models with PTO)

	5-6. FRONT SUPPORT AND CHARGING OIL PUMP MODULE

		Figure 5-3. Measuring Gear-Cavity Depth of the Pump Housing

		Figure 5-4. Measuring Gear-Cavity Diameter of the Pump Housing

		Figure 5-5. Measuring Gear Side Clearance of the Pump Housing

		Figure 5-6. Measuring Gear Tooth Tip Clearance

		Figure 5-7. Measuring Driven Gear Clearance to the Pump Housing

		Figure 5-8. Ground Sleeve Removal and Installation

	5-7. ROTATING CLUTCH MODULE

		Figure 5-9. Rotating Clutch Assembly

	5-8. C3

	5-9. MAIN SHAFT MODULE

		Figure 5-10. Measurement of Pilot and Journals of Main Shaft

	5-10. P1 PLANETARY MODULE

	5-11. P2 PLANETARY MODULE

	5-12. RETARDER MODULE

		Table 5-2. Temperature Sensor Chart

		Figure 5-11. P3 Carrier Turning Torque Check - Retarder Equipped

	5-13. REAR COVER MODULE

		Figure 5-12. P3 Carrier Turning Torque Check - Rear Cover Equipped

	5-14. CONTROL VALVE MODULE (Foldout 11)

		Figure 5-13. Main Pressure Valve Regulator Spring Tool

6 -TRANSMISSION ASSEMBLY

	6-1. SCOPE

	6-2. ASSEMBLY OF TRANSMISSION

		Figure 6-1. Main Housing and C3

		Figure 6-2. Rotating Clutch Module Installation

		Figure 6-3. Front Support

		Figure 6-4. P1 Planetary Module Installation Figure 6-6. Main Shaft Module Installation

		Figure 6-5. P2 Planetary Module and C5 Clutch Installation

		Figure 6-6. Main Shaft Module Installation

		Figure 6-7. Main Shaft Selective Shim Measurement With Retarder Module

		Figure 6-8. Main Shaft Selective Shim Measurement With Rear Cover Module

		Figure 6-9. Retarder Module Installation

		Figure 6-10. Retarder Module Bolts

		Figure 6-11. Rear Cover Module Installation

		Figure 6-12. Converter Housing Module Installation

		Figure 6-13. Torque Converter Module Installation and Selective Shim Measurement

		Table 6-1. Torque Converter Selective Shims

		Figure 6-14. Control Module Installation

		Figure 6-15. Externally Mounted Parts Installation

		Figure 6-16. Support Equipment Parts Installation

7 - WEAR LIMITS AND SPRING DATA

	7-1. WEAR LIMITS DATA

	7-2. SPRING DATA

		Table 7-1. Wear Limits Data

		Table 7-2. Spring Data

8 - CUSTOMER SERVICE

	8-1. OWNER ASSISTANCE

	8-2. SERVICE LITERATURE

		Table 8-1. HD 4000 

SUPPLEMENT TO SA2457B (HD 4070 Models Only)

	4-1. SCOPE

	4-2. DISASSEMBLY OF TRANSMISSION

		Figure 4-7a. Removal of Retarder & Output Shaft Module

		Figure 4-7b. Retarder & Output Shaft Module Bolts

		Figure 4-8a. Removal of Rear Cover & Output Shaft Module

		Figure 4-8b. Rear Cover & Output Shaft Module Bolts

		Figure 4-8c. Removal of C8 Adapter Housing Module

		Figure 4-8d Removal of P3 Planetary Module

	5-9. MAIN SHAFT MODULE

	5-11a. P3 PLANETARY MODULE (HD 4070 only)

	5-11b. C6 ADAPTER HOUSING MODULE

		Figure 5-10a. Compression of Spring & Retainer Assembly

		Figure 5-10b. Bottom View of C6 Adapter Housing & J35923-4

		Figure 5-10c. Removal of Ball Bearing from C6 Adapter Housing

		Figure 5-10d. Installation of Ball Bearing from C6 Adapter Housing

		Figure 5-10e. Compression of Spring & Retainer Assembly

		Figure 5-10f. Bottom View of C6 Adapter Housing & J35923-4

		Figure 5-10g. Installation of P4 Planetary Bushing

	5-12. RETARDER & P3 PLANETARY MODULE

	5-12a. RETARDER & OUTPUT SHAFT MODULE

		Figure 5-11a. Removal of Output Shaft from Retarder Housing

		Figure 5-11b. Installation of Cone & Roller Bearing onto Output Shaft

		Figure 5-11c. Bearing Retainer Nut Torque - Retarder Equipped

		Figure 5-11d. Output Shaft Turning Torque Check - Retarder Equipped

	5-13. REAR COVER MODULE

	5-13a. REAR COVER & OUTPUT SHAFT MODULE

		Figure 5-11e. Removal of Output Shaft Assembly

		Figure 5-12a. Installation of Cone & Roller Bearing onto Output Shaft

		Figure 5-12b. Bearing Retainer Locknut Torque - Rear Cover Equipped

		Figure 5-12c. Turning Torque Check - Rear Cover Equipped

	5-14. CONTROL VALVE MODULE

		Figure 5-14a. Disassembly of C6 Control Valve Body

	6-2. ASSEMBLY OF TRANSMISSION

		Figure 6-8a. Installation of P3 Planetary Module

		Figure 6-8b. Installation of C6 Adapter Housing Module

		Figure 6-8c. Tightening C6 Adapter Housing to Main Housing Bolts

		Figure 6-8ca. C6 Adapter Housing to Main Housing Bolt Torque Formula

		Figure 6-8d. P3 Planetary Shim Measurement (equipped with retarder)

		Figure 6-8e. P3 Planetary Shim Measurement (equipped with rear cover)

		Figure 6-8f. Tolerance Ring Locations

		Figure 6-10a. Installation of Retarder & Output Shaft Module

		Figure 6-10b. Installation of Retarder & Output Shaft Module Bolts

		Figure 6-10c. Installation of Output Shaft Oil Seal (equipped with retarder)

		Figure 6-11a. Installation of Rear Cover & Output Shaft Module

		Figure 6-11b. Rear Cover & Output Shaft Module Bolts

		Figure 6-11c. Output Shaft Turning Torque Check - Rear Cover Equipped

		Figure 6-11d. Installation of Output Shaft Oil Seal (equipped with rear cover)

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