Service Manual Allison Md3000
Allison 3000 4000 service manual pdf. 1.
SM2148EN Service Manual 3000 Product Family C M Y CM MY CY CMY K SM2148EN200612FRONT.pdf 3/30/07 1:11:25 PMSM2148EN200612FRONT.pdf 3/30/07 1:11:25 PM. SM2148EN 200612 Service Manual 3000 PRODUCT FAMILY C M Y CM MY CY CMY K SM2148EN200612SPINE.pdf 8/24/07 11:12:32 AMSM2148EN200612SPINE.pdf 8/24/07 11:12:32 AM. Printed in USA Copyright © 2007 Allison Transmission, Inc. Allison Transmission, Inc.
MANUAL DECEMBER 2010DECEMBER 2010. Operator’s 2010DECEMBER Manual OM3758EN AllisonTransmission 2010Uprate VOCATIONALMODELS PupilTransport/ShuttleSeries(PTS). Rebuild Parts Kit for Allison MD 3000 Series C3-C4, Includes Valve Body Sub Kit. 1992 - Up Allison MD 3000 Series OEM Factory Service Manual (SKU:. This manual provides troubleshooting information for the 3000 and 4000 Product. Allison Transmission service outlet for the currently applicable publication.
Box 894 Indianapolis, Indiana www.allisontransmission.com Allison Transmission VOCATIONAL MODELS Service Manual 2004 DECEMBER Rev. 1 2006 December SM2148EN 3000 EVS 3500 EVS 3000 HS 3500 HS 3000 MH 3500 MH 3000 PTS 3500 PTS 3000 RDS 3500 RDS 3000 SP 3200 SP 3500 SP 3700 SP 3000 TRV 3200 TRV MD 3060 MD 3066 MD 3560 MD 3070PT MD 3060P MD 3066P MD 3560P MD 3060R MD 3066R MD 3560R MD 3060PR MD 3066PR MD 3560PR B 300 B 400 B 300P B 400P B 300R B 400R B 300PR B 400PR T 250 T 310 T 255 T 325 T 260 T 350 T 265 T 375 T 270 T 280. ii Copyright © 2007 Allison Transmission, Inc. 3000 PRODUCT FAMILY SERVICE MANUAL NOTE: This publication is revised periodically to include improvements, new models, special tools, and procedures. A revision is indicated by letter suffix to the publication number. Check with your Allison Transmission service outlet for the currently applicable publica- tion. Additional copies of this publication may be purchased from authorized Allison Transmission service outlets.
Look in your tele- phone directory under the heading of Transmissions—Truck, Tractor, etc. ELECTRONIC CONTROL UNIT DISPLAYS AND BUTTON NAMES Shift Selector button and display names are printed in bold capital letters (Up) arrow, (Down) arrow, DISPLAY MODE, MONITOR, SELECT, etc.).
The actual message displayed (text and/or letters) is printed within double quotation marks (“O L”, “O K”, etc.). TRADEMARK USE The following trademarks are the property of the companies indicated:. Allison Diagnostic Optimized Connection™ (Allison DOC™) is a trademark of General Motors Corporation. Biobor® JF is the registered trademark for a biological inhibitor manufactured by Hammonds Fuel Additives Company. DEXRON® is a registered trademark of General Motors Corporation.
Spiralock® is a registered trademark of Spiralock of Michigan. Teflon® is a registered trademark of the DuPont Corporation. TranSynd™ is a trademark of Castrol, Ltd. Viton™ is a trademark of DuPont Corporation. WARNINGS, CAUTIONS, AND NOTES Three types of headings are used in this manual to attract your attention: NOTE: is used when an operating procedure, practice, etc., is essential to highlight. Is used when an operating procedure, practice, etc., which, if not correctly followed, could result in personal injury or loss of life. CAUTION: is used when an operating procedure, practice, etc., which, if not strictly observed, could result in damage to or destruction of equipment.
Copyright © 2007 Allison Transmission, Inc. Iii IT IS YOUR RESPONSIBILITY to be completely familiar with the Warnings and Cautions described in this Service Manual. These Warnings and Cautions advise against the use of specific service methods that can result in personal injury, damage to the equipment, or cause the equipment to become unsafe. It is, however, important to understand that these Warnings and Cautions are not exhaustive.
Allison Transmission could not possibly know, evaluate, and advise the service trade of all conceivable ways in which service might be done or of the possible hazardous consequences of each way. Consequently, Allison Transmission has not undertaken any such broad evaluation. Accordingly, ANYONE WHO USES A SERVICE PROCEDURE OR TOOL WHICH IS NOT RECOMMENDED BY ALLISON TRANSMISSION MUST first be thoroughly satisfied that neither personal safety nor equipment safety will be jeopardized by the service methods selected. Proper service and repair are important to the safe, reliable operation of the equipment. The service procedures recommended by Allison Transmission and described in this Service Manual are effective methods for performing service operations. Some of these service operations require the use of tools specifically designed for the purpose. The special tools should be used when and as recommended.
IMPORTANT SAFETY NOTICE. iv Copyright © 2007 Allison Transmission, Inc.
LIST OF WARNINGS This manual contains the following warnings — IT IS YOUR RESPONSIBILITY TO BE FAMILIAR WITH ALL OF THEM. If you leave the vehicle and the engine is running, the vehicle can move suddenly and you or others could be injured. If you must leave the engine running, do not leave the vehicle until you: Put the transmission in N (Neutral)and — Apply the parking brake and emergency brakes and make sure they are properly engagedand — Chock the wheels and take any other steps necessary to keep the vehicle from moving. Avoid contact with the hot fluid or the sump when draining transmission fluid.
Direct contact with the hot fluid or the hot sump may result in bodily injury. While conducting a stall check, the vehicle must be positively prevented from moving. Apply the parking brake and service brake, and chock the wheels securely. Warn personnel to keep clear of the vehicle and its travel path. Failure to do so can cause serious injury.
Use appropriate safety equipment such as safety glasses, safety shoes, and gloves. Do not burn discarded Teflon® seals; toxic gases are produced by burning Teflon®. Never dry bearings by spinning them with compressed air.
A spinning bearing can disintegrate, allowing balls or rollers to become lethal flying projectiles. Also, spinning a bearing without lubrication can damage the bearing.
3000 Product Family transmission dry weights are as follows: —basic configuration 243 kg (535 lb) —with PTO provision 261 kg (575 lb) —with retarder 279 kg (615 lb) —with PTO provision and retarder 297 kg (655 lb) —with PTO provision, retarder, 336.5 kg (740 lb) and integral sump cooler 3700 SP and MD 3070PT 530 kg (1170 lb) Use proper tools and lifting equipment when installing or removing a transmission from the repair stand. The transfer case module assembly weighs approximately 270 kg (595 lb). The control module assembly weighs approximately 25 kg (56 lb). Handle carefully to avoid personnel injury or control module damage.
The control module assembly used in a 3700SP and MD 3070PT weighs approximately 29 kg (65 lb). The retarder module assembly weighs approximately 64 kg (141 lb).
Use care to prevent injury to personnel while handling the retarder module assembly. Piston springs are highly compressed. Be extremely careful during removal and installation.
Personal injury can occur if the spring force is not controlled. Transmissions installed in overhaul stands must be positioned vertically before installing control module. Failure to do so could result in personal injury. Copyright © 2007 Allison Transmission, Inc. V TABLE OF CONTENTS Section 1. GENERAL INFORMATION 1–1. SCOPE OF MANUAL a.
Content and Organization.1–1 b. Illustrations.1–1 c. Maintenance Information. SUPPLEMENTARY INFORMATION.1–6 1–3. ORDERING PARTS a. Transmission Nameplate.1–6 b. Parts Catalog.1–6 1–4.
GENERAL DESCRIPTION a. Major Modules.1–6 b. Unique Features.1–6 1–5. MAJOR MODULES a. Input Module.1–7 b.
Torque Converter.1–7 c. Power Takeoff Provision.1–7 d. Main Housing and Gear Module.1–7 e. Range Clutches.1–7 f.
Gearing Ratios.1–7 g. Control System and Electronic Control Unit (ECU).1–7 h.
Oil Filters.1–7 i. Transmission Fluid Coolers. Output Configuration.1–7 1–6. MODEL DESIGNATION CODE a.
3000 Product Family Vocational Model Standard and Optional Features.1–8 1–7. Before Starting.1–9 b. DO NOT SHIFT or CHECK TRANS Light.1–9 c. Entering Diagnostic Mode.1–9 d. Diagnostic Codes.1–9 e. Displaying Diagnostic Codes.1–9 f.
Diagnostic Code Displays.1–9 g. Exiting Diagnostic Mode.1–9 1–8. PRESERVATION AND STORAGE a. Storage.1–9 b.
Preservation Methods. One Year Storage (Without Fluid).1–10 d. One Year Storage (With Fluid).1–10 1–9. RESTORING TRANSMISSION TO SERVICE a. Transmission Exterior.
Sealed Breather and Openings. New Transmissions. Stored Without Fluid. Stored With Fluid. OPERATING INSTRUCTIONS. SPECIFICATIONS AND DATA. ELECTROMAGNETIC/RADIO FREQUENCY INTERFERENCE.
1–12 Section 2. PREVENTIVE MAINTENANCE 2–1. PERIODIC INSPECTION AND CARE a. Exterior Cleaning and Inspection. IMPORTANCE OF PROPER FLUID LEVEL a. Transmission Fluid.
Oil Level Sensor. Electronic Controls and Protection Circuits. ELECTRONIC FLUID LEVEL CHECK (WHEN AN OPTIONAL OLS IS PRESENT—FULL-FUNCTION PUSHBUTTON OR LEVER SHIFT SELECTORS) a. Fluid Level Check Procedure. ELECTRONIC FLUID LEVEL CHECK (WHEN AN OPTIONAL OLS IS PRESENT—STRIP TYPE PUSHBUTTON SHIFT SELECTORS) a. Fluid Level Check Procedure (WTEC II). Fluid Level Check Procedure (WTEC III).
MANUAL FLUID LEVEL CHECK PROCEDURE a. Consistency of Readings. COLD CHECK a. Cold Check Procedure. 2–4 TABLE OF CONTENTS. vi Copyright © 2007 Allison Transmission, Inc. 3000 PRODUCT FAMILY SERVICE MANUAL 2–8.
Procedure.2–5 2–9. KEEPING FLUID CLEAN a. Foreign Material.2–5 2–10. FLUID RECOMMENDATIONS.2–5 2–11. FLUID AND FILTER CHANGE INTERVAL a.
Fluid and Filter Changes.2–6 b. Fluid Analysis.2–6 2–12. FLUID CONTAMINATION a.
Water.2–6 b. Engine Coolant.2–7 c. Metal.2–7 2–13. FLUID AND FILTER CHANGE PROCEDURE a. Drain Fluid.2–7 b.
Replace Filters—3000 Product Family.2–7 c. Replace Filters—3700 SP or MD 3070PT. Refill Transmission.2–9 2–14. Location and Purpose.2–9 b. Maintenance.2–9 2–15. CHECKING CLUTCH PRESSURES a. Transmission and Vehicle Preparation.2–10 b.
Recording Data.2–10 c. Comparing Recorded Data to Specifications.2–11 d. Pressure Specifications for all 3000 Product Family Transmissions.2–12 2–16. TRANSMISSION STALL TEST AND NEUTRAL COOL-DOWN CHECK a. Stall Testing Preparation.
Performing a Transmission Stall Test. Driving Transmission Stall Test.
Driving Transmission Stall Testing Preparation. Performing a Driving Transmission Stall Test.
Neutral Cool-Down Check Procedure. Transmission Stall Test Results.2–15 2–17. FLUID LEAK DIAGNOSIS a. Finding the Leak. Powder Method. Black Light and Dye Method.
Possible Points of Fluid Leaks and Their Causes. Repairing the Leak. OUTPUT FLANGE/YOKE AND OIL SEAL MAINTENANCE (All, Except 3700 SP and MD 3070PT) a. YOKE AND OIL SEAL MAINTENANCE (3700 SP and MD 3070PT) a.
ON-VEHICLE MAINTENANCE. 2–19 Section 3. GENERAL OVERHAUL INFORMATION 3–1. TOOLS AND EQUIPMENT a. Improvised Tools and Equipment. Special Tools.
Mechanic’s Tools and Shop Equipment. REPLACEMENT PARTS a. Ordering Information.
Parts Normally Replaced at Overhaul. CAREFUL HANDLING. CLEANING AND INSPECTION a. Dirt Causes Malfunction. Cleaning Parts. Cleaning Bearings. Keeping Bearings Clean.
Inspecting Bearings. Inspecting Cast Parts and Machined Surfaces. Inspecting Bushings and Thrust Washers. Inspecting Sealrings and Gaskets. Inspecting Gears. Inspecting Splined Parts. 3–8.
Copyright © 2007 Allison Transmission, Inc. Vii TABLE OF CONTENTS 3–5. CLEANING AND INSPECTION (cont’d) k. Inspecting Threaded Parts.3–8 l.
Inspecting Retaining Rings.3–8 m. Inspecting Springs.3–8 n.
Inspecting Clutch Plates.3–8 o. Inspecting Swaged and Interference-Fit Parts.3–8 p. Inspecting Retainer and Ball Assembly in Retarder Stator.3–9 q. Inspecting Sealing Surfaces.3–9 3–6.
ASSEMBLY PROCEDURES a. Parts Lubrication.3–9 b. Grease Used for Assembly.3–9 c. Sealing Compounds and Nonsoluble Greases.3–9 d. Clutches and Pistons.3–9 e. Threaded Plugs and Hydraulic Fittings.3–9 f. Coated Threaded Fasteners.3–9 g.
Lip-Type Seals.3–9 h. Butt-Joint Sealrings.3–10 i. Bearings.3–10 j. Electrical Components.3–10 3–7.
REMOVING (OR INSTALLING) TRANSMISSION a. Drain Fluid.3–10 b. Disconnecting Controls.3–11 c. Uncoupling From Driveline, Vehicle, and Engine.3–12 d. Removing the Transmission.3–12 3–8. WEAR LIMITS.3–12 3–9.
SPRING SPECIFICATIONS.3–12 3–10. TORQUE SPECIFICATIONS.3–12 Section 4. TRANSMISSION DISASSEMBLY 4–1. Section.4–1 b.
Procedures.4–1 c. Illustrations.4–1 d. General Information.4–1 e. Foldouts.4–1 4–2. DISASSEMBLY OF TRANSMISSION a. Mounting Transmission on Repair Stand.
Removal of Common Externally- Mounted Parts. Removal of Speed Sensors. Removal of Integral Oil Cooler. Removing Integral Retarder Sump Oil Cooler. Removal of Power Takeoff(s). Removal of Transfer Case Module— 3700 SP or MD 3070PT.
Removal of Control Module. Removal of Torque Converter Module. Removal of Converter Housing Module. Removal of Retarder Module (Units Built Before 1/98). Removal of Retarder Module (Units Built Beginning 1/98) and Units Starting With S/N ).
Removal of Transfer Case Adapter Housing Module. Removal of Rear Cover Module. Removal of Main Shaft Module. Removal of P2 Module, C5 Clutch Plates, and P1 Module. Removal of Front Support/Charging Pump Module and Rotating Clutch Module. Removal of C3/C4 Clutch Assembly From Main Housing Module.
4–9 Section 5. MODULE REBUILD 5–1. GENERAL INFORMATION FOR MODULE REBUILD.
TORQUE CONVERTER MODULE a. 5–2 TABLE OF CONTENTS.
6 Speed Manual Allison Transmission
viii Copyright © 2007 Allison Transmission, Inc. 3000 PRODUCT FAMILY SERVICE MANUAL 5–4. TORQUE CONVERTER HOUSING MODULE (Models Without PTO Provision) a. TORQUE CONVERTER HOUSING MODULE (Models With PTO Provision) a. Module Disassembly.
Disassembly of the Bearing Retainer. Disassembly of the PTO Gear Assembly. Assembly of the PTO Gear Assembly. Assembly of the Bearing Retainer Assembly. Module Assembly.
FRONT SUPPORT AND CHARGING OIL PUMP MODULE a. Module Disassembly. Assembly of the Front Support. Assembly of the Pump Housing. ROTATING CLUTCH MODULE a.
C3/C4 AND MAIN HOUSING MODULE a. MAIN SHAFT MODULE a. Disassembly (3000 Product Family Models, Except 3500, MD 3560, 3700 SP, and MD 3070PT). Assembly (3000 Product Family Models, Except 3500, MD 3560, 3700 SP and MD 3070PT). Module Disassembly (3500 and MD 3560 Models).5–18 d.
Module Assembly (3500 and MD 3560 Models).5–18 e. Module Disassembly (3700 SP and MD 3070PT Models).5–18 f. Module Assembly (3700 SP and MD 3070PT Models).5–18 5–10. P1 PLANETARY MODULE a. P2 PLANETARY MODULE a. RETARDER MODULE a.
Manual Allison Transmission
Disassembly of Retarder Valve Body (Units Built Before 1/98). Removal of Wiring Harness and Temperature Sensor.
Disassembly of Retarder Housing. Disassembly of P3 Planetary Carrier Assembly. Disassembly of Retarder Stator Assembly. Assembly of Retarder Stator. Assembly of P3 Planetary Carrier Assembly.
Assembly of Retarder Housing Assembly. Installation of Wiring Harness Assembly.
Assembly and Installation of Retarder Control Body Assembly. Disassembly of Retarder Valve Body (Units Built Starting 1/98). Disassembly of Retarder Housing. Disassembly of P3 Planetary Carrier Assembly.
Disassembly of Retarder Stator Assembly. Assembly of Retarder Stator. Assembly of P3 Planetary Carrier Assembly.
Assembly of Retarder Housing Assembly. Assembly and Installation of Retarder Control Body Assembly.
Disassembly of Retarder Valve Body (Units Starting With S/N ). Disassembly of Retarder Housing. Disassembly of P3 Planetary Carrier Assembly.
Disassembly of Retarder Stator Assembly. Assembly of Retarder Stator. 5–35. Copyright © 2007 Allison Transmission, Inc. Ix TABLE OF CONTENTS 5–12.
RETARDER MODULE (cont’d) x. Assembly of P3 Planetary Carrier Assembly.5–35 y. Assembly of Retarder Housing Assembly.5–36 z. Assembly and Installation of Retarder Control Body Assembly.5–37 5–13.
REAR COVER MODULE a. Disassembly of the P3 Planetary Carrier Assembly.
Disassembly of the Rear Cover Assembly. Assembly of Rear Cover. Assembly of the P3 Planetary Carrier Assembly. Completion of the Rear Cover Module. ADAPTER HOUSING AND P3 OVERHAUL a.
Disassembly.5–40 b. Assembly.5–41 5–15. SCAVENGE PUMP OVERHAUL a. Disassembly.5–42 b. Assembly.5–44 5–16.
TRANSFER CASE MODULE a. Disassembly of Transfer Case Module.
Disassembly of C6 Clutch. Assembly of C6 Clutch. Disassembly of C7 Clutch. Assembly of C7 Clutch Housing.
Disassembly of Oil Pump.5–48 g. Assembly of Oil Pump.5–48 h. Disassembly of P4 Carrier. Assembly of P4 Carrier.
Disassembly of Drive, Idler, and Driven Gears. Assembly of Drive, Idler, and Driven Gears. Disassembly of the Front Output Housing and Front Output Shaft.
Assembly of the Front Output Housing and Front Output Shaft. Disassembly of the Rear Output Housing.
Assembly of the Rear Output Housing. Output Housing Bearing Preload Procedures. Disassembly of C7 Control Valve Body. Assembly of C7 Control Valve Body Assembly. Assembly of Transfer Case Module.
CONTROL VALVE MODULE a. Removal of Filters. Removal of Electrical Components and Sensors. Disassembly of the Rotating Clutch Solenoid Body. Disassembly of the Stationary Clutch Solenoid Body. Disassembly of C6 Control Valve Body. Disassembly of the Main Valve Body.
Disassembly of the Channel Plate. Assembly of the Channel Plate. Assembly of the Main Valve Body. Assembly of C6 Control Valve Body. Assembly of the Stationary Clutch Solenoid Body. Assembly of the Rotating Clutch Solenoid Body.
Installation of the Wiring Harness Assembly and Cover Plate. 5–59 Section 6. TRANSMISSION ASSEMBLY 6–1. General Information.
ASSEMBLY OF TRANSMISSION a. Assembly of C3/C4 Clutch.
Installation of the Rotating Clutch Module. Installation of the Front Support/ Charging Pump Module. 6–1. x Copyright © 2007 Allison Transmission, Inc.
3000 PRODUCT FAMILY SERVICE MANUAL 6–2. ASSEMBLY OF TRANSMISSION (cont’d) d. Installation of the P1 Planetary Module.
Installation of the P2 Planetary Module. Installation of the C5 Clutch Pack. Installation of the Main Shaft. Main Shaft Selective Shim Measurement For Close Ratio Models. Main Shaft Selective Shim Measurement (Wide Ratio Models). Main Shaft Selective Shim Measurement For 3700 SP and MD 3070PT.6–5 k. Installation of Retarder Module (Units Built Before 1/98).
Installation of Retarder Module (3000 Product Family Units Built Starting 1/98).6–6 m. Installation of Rear Cover Module. Installation of Transfer Case Adapter Housing. Installation of Transfer Case Module. Installation of the Converter Housing Module. Installation of the Torque Converter Module.
Installation of the Control Module. Installation of Power Takeoff(s). Installation of Integral Oil Cooler. Installation of Integral Retarder Sump Oil Cooler. Installation of Speed Sensors. Installation of Common Externally- Mounted Parts.
Removal of Transmission From Repair Stand. 6–15 Section 7. WEAR LIMITS AND SPRING DATA 7–1. WEAR LIMITS DATA a. Maximum Variations. Cleaning and Inspection.
SPRING DATA a. Spring Replacement. 7–1 Section 8. CUSTOMER SERVICE 8–1. OWNER ASSISTANCE.
SERVICE LITERATURE. 8–2. Copyright © 2007 Allison Transmission, Inc. Xi LIST OF SUPPORTING ILLUSTRATIONS (Back of Service Manual) CROSS-SECTION VIEWS 1.
3000 Product Family Transmission 2. MD 3066 Transmission with Retarder (Prior To January 1, 1998) 3. 3000 Product Family (Except 3000 HS and 3700 SP) Transmission with PTO Provision and Retarder (Beginning January 1, 1998) 4. 3000 Product Family Transmission (Except 3000 HS and 3700 SP) with PTO Provision and Retarder (Starting with S/N ) 5.
3500 and MD 3560 Transmission 6. 3700 SP and MD 3070PT Transmission EXPLODED VIEWS 7.
Torque Converter Module 8,A. Converter Housing Module, Without PTO Provision 8,B. Converter Housing Module, With PTO Provision 9,A. Front Support and Oil Pump Module 9,B. Rotating Clutch Module 10,A. Main Housing Module 10,B. 3000 Product Family Main Shaft Module (Except 3500, 3700 SP, MD 3560, and MD 3070PT) 11,A.
Main Shaft Module (3500 and MD 3560) 11,B. Main Shaft Module (3700 SP and MD 3070PT) 12,A.
P1 Planetary Module 12,B. P2 Planetary Module 13,A. Retarder and P3 Planetary Module (Prior To 1/98) 13,B.
Retarder and P3 Planetary Module (Beginning 1/98) 13,C. Retarder and P3 Planetary Module (Starting with S/N ) 13,D. Rear Cover and P3 Planetary Module 14,A. Transfer Case, Special Tools 14,B.
Transfer Case, Special Disassembly/Assembly Instructions 15. Front Main Transfer Case 16. Rear Main Transfer Case 17,A. Control Valve Module (Prior To S/N ) 17,B. Control Valve Module (S/N To S/N ) 17,C. Control Valve Module (Starting With S/N ) 18,A.
Output Flange and Yoke 18,B. Transfer Case Adapter Housing 19,A. Oil Cooler 19,B. Integral Sump Cooler 19,C Scavenge Pump 19,D Support Equipment HYDRAULIC SCHEMATIC 20. 3000 Product Family—Neutral TABLE OF CONTENTS. xii Copyright © 2007 Allison Transmission, Inc. 3000 PRODUCT FAMILY SERVICE MANUAL NOTES.
Copyright © 2007 Allison Transmission, Inc. SCOPE OF MANUAL a. Content and Organization. This Service Man- ual describes overhaul procedures for 3000 Product Family automatic transmissions (Figures 1–1 through 1–8). The major transmission components are described and their functions explained. Detailed instructions are provided for disassembly, rebuild, and re-assembly. Part inspection instructions are in Section 3.
Wear limits and spring data are in Section 7.