Allison Transmission Sm2148En 1998 Service Manual-21516A320004.pdf
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B300

INTRODUCTION

	ELECTRONIC CONTROL UNIT AND DIAGNOSTIC DATA READER

	TRADEMARK USE

	IMPORTANT SAFETY NOTICE

	WARNINGS, CAUTIONS, AND NOTES

	LIST OF WARNINGS

TABLE OF CONTENTS

LIST OF SUPPORTING ILLUSTRATIONS

1 - GENERAL INFORMATION

	1-1. SCOPE OF MANUAL

	1-2. SUPPLEMENTARY INFORMATION

	1-3. ORDERING PARTS

	Figure 1-1. Model MD(P) 

	Figure 1-2. Model MD(P) 

	Figure 1-3. Model MD(R) 

	Figure 1-4. Model MD(R) 

	Figure 1-5. Model MD(R) 

	Figure 1-6. Model MD 3070PT Transmission - Right-Front View

	Figure 1-7. Model MD 3070PT Transmission - Left-Rear view

	Figure 1-8. Transmission Nameplate

	1-4. GENERAL DESCRIPTION

	1-5. MAJOR MODULES

	1-6.MODEL DESIGNATION CODE

	1-7. DIAGNOSIS

	1-8. PRESERVATION AND STORAGE

	1-9. RESTORING TRANSMISSION TO SERVICE

	1-10. OPERATING INSTRUCTIONS.

	1-11. SPECIFICATIONS AND DATA

	Table 1-1. Specifications And Data Chart*

	1-12. ELECTROMAGNETIC

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 (WHEN AN OPTIONAL OLS IS PRESENT - FULL FUNCTION PUSHBUTTON OR LEVER SHIFT SELECTORS)

	2-5. ELECTRONIC FLUID LEVEL CHECK (WHEN AN OPTIONAL OLS IS PRESENT - STRIP TYPE PUSHBUTTON SHIFT SELECTORS)

	2-6. MANUAL FLUID LEVEL CHECK PROCEDURE

	2-7. COLD CHECK

		Figure 2-1. Fluid Dipstick Markings

	2-8. HOT CHECK

	2-9. KEEPING FLUID CLEAN

	2-10. FLUID RECOMMENDATIONS

	2-11. FLUID AND FILTER CHANGE INTERVAL

		Table 2-1. Transmission Fluid Operating Temperature Requirements

		Table 2-2. Transmission Fluid and Filter Change

		Table 2-3. Fluid Oxidation Measurement Limits

	2-12. FLUID CONTAMINATION

	2-13. FLUID AND FILTER CHANGE PROCEDURE

		Figure 2-2. Filter Change

		Figure 2-3. MD 3070PT Filter Change

		Table 2-4. Fluid Fill Quantities

	2-14. BREATHER

	2-15. CHECKING CLUTCH PRESSURES

		Figure 2-4. Clutch Pressure Check Points

		Table 2-5. Clutch Pressure Test Conditions

		Table 2-6. Main Pressure and Clutch Pressure Specifications

	2-16. TRANSMISSION STALL TEST

	2-17. FLUID LEAK DIAGNOSIS

	2-18. OUTPUT FLANGE

		Figure 2-5. Output Flange and Oil Seal - MD 3000

		Figure 2-6 Installing Redesign Two-Bolt Flange Retention Kit

		Figure 2-7. Output Flange and Oil Seal - MD 3070PT

	2-19. YOKE AND OIL SEAL MAINTENANCE (MD 3070PT)

	2-20. ON-VEHICLE MAINTENANCE

3 - GENERAL OVERHAUL INFORMATION

	3-1. SCOPE

	3-2. TOOLS AND EQUIPMENT

		Figure 3-1. Work Table

		Figure 3-2. Overhaul Stand

		Figure 3-3. Special Tools

		Table 3-1. Special Tools*

		Figure 3-4. Method of Measuring Clutch Plate Cone

	3-3. REPLACEMENT PARTS

	3-4. CAREFUL HANDLING

	3-5. CLEANING AND INSPECTION

	3-6. ASSEMBLY PROCEDURES

	3-7. REMOVING (OR INSTALLING) TRANSMISSION

		Figure 3-5. Disconnect Locations (Retarder Models Prior To 1

		Figure 3-6. Disconnect Locations (Retarder Models Beginning 1

		Figure 3-7. Disconnect Locations (MD3070PT)

	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. MD 3070PT Repair Stand Brackets

		Figure 4-2. Common Externally-Mounted Parts Removal

		Figure 4-3. Output Speed Sensor

		Figure 4-4. Scavenge Pump Removal

		Figure 4-5. Transfer Case Module Removal

		Figure 4-6. Control Module Removal

		Figure 4-7. Torque Converter Module Removal

		Figure 4-8. Converter Housing Module Removal

		Figure 4-9. Retarder Module Removal

		Figure 4-10. Adapter Housing Removal

		Figure 4-11. Rear Cover Module Removal

		Figure 4-12. Main Shaft Module Removal

		Figure 4-13. P2 Module and C5 Clutch Plates

		Figure 4-14. P1 Module

		Figure 4-15. Front Support

		Figure 4-16. Rotating Clutch Module Removal

		Figure 4-17. C3

5 - MODULE REBUILD

	5-1. SCOPE

	5-2. GENERAL INFORMATION FOR MODULE REBUILD

		Figure 5-1. Stator Roller

	5-3. TORQUE CONVERTER MODULE

		Figure 5-2. Torque Convertor Selective Shim Procedure

		Table 5-1. Torque Converter Selective Shims

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

	5-5. TORQUE CONVERTER HOUSING MODULE (Models With PTO Provision)

	5-6. FRONT SUPPORT AND CHARGING OIL PUMP MODULE

		Figure 5-3 Oil Pump Drive Hubs

	5-7. ROTATING CLUTCH MODULE

	5-8. C3

		Figure 5-4a. Measuring Gear-Cavity Depth In the Pump Housing

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

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

		Figure 5-6. Measuring Gear Tooth Tip Clearance In the Pump Housing

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

		Figure 5-8. Ground Sleeve Removal And Installation

		Figure 5-9. Rotating Clutch Assembly

		Figure 5-10. Redesigned C1 Pressure Plates

	5-9. MAIN SHAFT MODULE

	5-10. P1 PLANETARY MODULE

		Figure 5-11. Carrier Indexing Ring Wear

		Figure 5-12. Sharp Edge vs. Radius Edge On Planetary Splindles

	5-11. P2 PLANETARY MODULE

	5-12. RETARDER MODULE

	5-13. REAR COVER MODULE

		Figure 5-13. Solenoid resistance vs Temperature

		Figure 5-14. Temperature Sensor Chart

		Figure 5-15. Tigtening Output Spanner Nut

		Figure 5-16. P3 Carrier Turning Torque Check - Retarder Equipped Models

		Figure 5-17. Retarder Temperature Sensor Resistance vs Temperature (Units Built Starting 1

		Figure 5-18. Carrier Turning Torque Check Models Without Retarder

	5-14. ADAPTER HOUSING AND P3 OVERHAUL

	5-15. TRANSFER CASE MODULE

		Figure 5-19. Transfer Case Fitting And Screen Installation

	5-16. CONTROL VALVE MODULE

6 - TRANSMISSION ASSEMBLY

	6-1. SCOPE

	6-2. ASSEMBLY OF TRANSMISSION

		Figure 6-1. P2 Planetary Module and C5 Clutch Installation

		Figure 6-2. Rotating Clutch Module Installation

		Figure 6-3 Front Support

		Figure 6-4. P1 Planetary Module Installation

		Figure 6.5. P2 Planetary Module and C5 Clutch Installation

		Figure 6-6. Main Shaft Installation

		Figure 6-7. Main Shaft Selective Shim Measurement With Retarder Module - MD 3060

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

		Figure 6-9. Selective Shim Measurement For MD 3070PT

		Figure 6-10. Retarder Module Bolts (Units Built Prior to 1

		Figure 6-11. Retarder Module Bolts (Units Built Starting 1

		Figure 6-12. Rear Cover Module Installation

		Figure 6-13. Transfer Case Adapter Housing Installation

		Figure 6-14. Transfer Case Module Installation

		Figure 6-15. Converter Housing Module Installation

		Figure 6-16. Torque Converter Module Installation and Selective Shim Measurement

		Table 6-1. Torque Converter Selective Shims

		Figure 6-17. Control Module Installation

		Figure 6-18. Power Takeoff(s) Installation

		Figure 6-19. Externally-Mounted Parts Installation

		Figure 6-20. MD 3070PT - Scavenge Pump Installation

		Figure 6-21. Removing Transmission From Repair Stand

7 - WEAR LIMITS AND SPRING DATA

	7-1. WEAR LIMITS DATA

		Table 7-1. Wear Limits Data

	7-2. SPRING DATA

		Table 7-2. Spring Data

8 -CUSTOMER SERVICE

	8-1. OWNER ASSISTANCE

	8-2.SERVICE LITERATURE

		Table 8-1. Service Literature

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