1.1.1.

1 DRIVERSMANUAL

Drivers instruction

ALLISON 3000 / 4000

Transmission

DOCUMENT > TD 1106-02 E

EDITION > 02/2006
 INDEX

1 INTRODUCTION..........................................................................................2
1.1 KEEPING THAT ALLISON ADVANTAGE.............................................................................. 2
1.2 A BRIEF DESCRIPTION OF THE ALLISON MD, HD, TRANSMISSIONS........................... 4
1.3 ELECTRONIC CONTROL SYSTEM..................................................................................... 4
1.4 TORQUE CONVERTER....................................................................................................... 5
1.5 PLANETARY GEARS AND CLUTCHES............................................................................... 8
1.6 COOLER CIRCUIT............................................................................................................... 8
1.7 RETARDER (IF PRESENT)...................................................................................................... 8
2 SHIFT SELECTOR......................................................................................9
2.1 INTRODUCTION.................................................................................................................. 9
2.2 PUSHBUTTON SHIFT SELECTOR (WITH DIGITAL DISPLAY)................................................ 10
2.2.1 RANGE SELECTION Reverse....................................................................................11
2.2.2 RANGE SELECTION Neutral......................................................................................12
2.2.3 RANGE SELECTION Drive.........................................................................................13
2.2.4 RANGE SELECTION 1-6............................................................................................14
3 DRIVING TIPS...........................................................................................15
3.1 CHECK TRANS LIGHT....................................................................................................... 15
3.2 DIAGNOSTIC CODES........................................................................................................ 16
3.3 DIAGNOSTIC CODE DISPLAY PROCEDURE................................................................... 16
3.4 ACCELERATOR CONTROL............................................................................................... 17
3.5 DOWNSHIFT AND DIRECTION CHANGE INHIBITOR FEATURE.................................... 17
3.6 USING THE ENGINE TO SLOW THE VEHICLE................................................................ 18
3.7 USING THE HYDRAULIC RETARDER (IF PRESENT).......................................................... 19
3.8 RANGE PRESELECTION.................................................................................................. 21
3.9 COLD WEATHER STARTS................................................................................................ 22
3.10 DRIVING ON SNOW OR ICE............................................................................................. 22
3.11 ROCKING OUT.................................................................................................................. 23
3.12 HIGH FLUID TEMPERATURE............................................................................................ 23
3.13 PARKING BRAKE............................................................................................................... 24
3.14 TOWING OR PUSHING..................................................................................................... 25
3.15 CRUISE CONTROL OPERATION (IF PRESENT)................................................................. 25
3.16 TURNING OFF THE VEHICLE........................................................................................... 25
4 POWER TAKEOFF OPERATION..............................................................26
4.1 ENGINE-DRIVEN POWER TAKEOFF (PTO)..................................................................... 26
5 CARE AND MAINTENANCE.....................................................................27
5.1 PERIODIC INSPECTIONS................................................................................................. 27
5.2 PREVENT MAJOR PROBLEMS......................................................................................... 27
5.3 IMPORTANCE OF PROPER FLUID LEVEL....................................................................... 28
5.4 FLUID LEVEL CHECK USING THE PUSHBUTTON.......................................................... 29
5.5 MANUAL FLUID CHECK PROCEDURE............................................................................ 31
5.5.1 COLD CHECK................................................................................................................. 31
5.5.2 HOT CHECK.................................................................................................................... 32
5.6 RECOMMENDED AUTOMATIC TRANSMISSION FLUID AND VISCOSITY GRADE........33
5.7 KEEPING FLUID CLEAN.................................................................................................... 34
5.8 FLUID AND INTERNAL FILTER CHANGE INTERVAL RECOMMENDATIONS.................34
6 DIAGNOSIS...............................................................................................35
6.1 DIAGNOSTIC CODES........................................................................................................ 35
WARNINGS, CAUTIONS, AND NOTES

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. The vehicle manufacturer is responsible for providing information related to the
operation of vehicle systems (including appropriate warnings, cautions, and notes).

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 OR THE VEHICLE
MANUFACTURER MUST first be thoroughly satisfied that neither personal safety nor
equipment safety will be jeopardized by the service methods selected.

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

Three types of headings are used in this manual to attract your attention. These
warnings and cautions advise of specific methods or actions that can result in
personal injury, damage to the equipment, or cause the equipment to become
unsafe.

WARNING: A warning is used when an operating procedure, practice,

etc., if not correctly followed, could result in
personal injury or loss of life.

CAUTION: A caution is used when an operating

procedure,
practice, etc., if not strictly observed, could result in damage to or
destruction of equipment.

NOTE: A note is used when an operating

procedure, practice, etc., is essential to highlight.

TRADEMARK INFORMATION

TranSynd is a trademark of Castrol Ltd.

DEXRON is a registered trademark of General Motors Corporation.
Allison DOC is a trademark of General Motors Corporation.

1
1 INTRODUCTION

1.1 KEEPING THAT ALLISON ADVANTAGE

Allison 3000 and 4000 Product Families transmissions are rugged and designed to
provide long, trouble-free service.

This handbook will help you gain maximum benefits from your ALLISON-equipped
vehicle.

2
 Abbreviations

ABS Anti-lock Brake System

DOC Diagnostic Optimized Connection
DTC Diagnostic Trouble Code
ECM Electronic Trouble Code
EMI Electro Magnetic Interference
FCC Federal Communications Commission
KOH Potassium Hydroxide
MIL Military Specifications
OEM Original Equipment Manufacturer
OLS Oil Level Sensor
PTO Power Take Off
RFI Radio Frequency Interference
TAN Total Acid Number
TCM Transmission Control Module
TPS Throttle Position Sensor
WTEC World Transmission Electronic Control

3
 3000 and 4000 Product Families Transmissions

3000 product family 4000 product family

4
1.2 A BRIEF DESCRIPTION OF THE ALLISON MD, HD,
TRANSMISSIONS

Included in the Allison On-Highway Transmission family are the 3000 and 4000 product
families, transmissions. The transmissions described in this handbook include the 4th
generation control system, a torque converter with lockup and torsion damper, and three
planetary gear sets . These transmissions may also contain an integral retarder and/or power
takeoff (PTO).

1.3 ELECTRONIC CONTROL SYSTEM

All Allison 3000 and 4000 product families transmissions come standard with Allison
4th generation controls. The system consists of five major components connected by
customer-furnished wiring harnesses.

Transmission Control Module (TCM)

Engine throttle position sensor (or direct electronic communication),

Three speed sensors
Remote shift selector
Control module (which contains solenoid valves, a pressure switch, and an
optional oil level sensor).

The throttle position sensor (or engine-to-transmission communication link), speed

sensors, pressure switch, and shift selector transmit information to the TCM. The
TCM processes this information and then sends signals to actuate specific solenoids
located on the control module in the transmission. These solenoids control both
loncoming and off going clutch pressures to provide closed-loop shift control by
matching rpm during a shift to a previously established desired profile that is
programmed into the TCM.

A feature of Allison 4th generation controls is autodetect. Autodetect is active within

the first several engine starts, depending upon the component or sensor being
detected.
These engine start cycles begin from when the transmission is installed during
vehicle manufacture. Autodetect searches for the presence of the following
transmission components or source of data inputs:

Retarder Present, Not Present

Oil Level Sensor (OLS) Present, Not Present
Throttle Analog, J 1587, J 1939
Engine Coolant Temperature Analog, J 1939, J 1587

Seek help from Terberg Benschop BV when any of the above items are present, but
are not responding properly.

5
Another feature of the Allison 3000 and 4000 product families transmission is its ability
to adapt or learn as it operates. Each shift is measured electronically, stored and
used by the TCM to adapt or learn the optimum conditions for future shifts.

NOTE: Allison 4th generation electronic control systems are designed and
manufactured to comply with all FCC and other guidelines regarding radio
frequency interference/electromagnetic interference (RFI/EMI) for
transportation electronics. Manufacturers, assemblers, and installers of
radio-telephone or other two-way communication radios have the sole
responsibility to correctly install and integrate those devices into Allison
3000 and 4000 product families transmission-equipped vehicles to
customer
satisfaction.

The TCM is programmed to provide the most suitable operating characteristics for a
specific application. This handbook does not attempt to describe all of the possible
combinations. The information contained herein describes only the operating
characteristics most frequently requested by the vehicle manufacturer.

1.4 TORQUE CONVERTER

The torque converter consists of four elements pump, turbine, and stator.
The pump is the input element and is driven directly by the engine.
The turbine is the output element and is hydraulically driven by the pump.
The stator is the reaction(torque multiplying) element.
The lockup clutch mechanically couples the pump and the turbine when engaged;
controlled by TCM

When the pump turns faster than the turbine, the

torque converter is multiplying torque. When the turbine approaches the speed of the
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.

The lockup clutch is located inside the torque converter and consists of
three elements piston, clutch plate/damper, and backplate. The piston and
backplate are driven by the engine. The clutch plate/damper, located between the
piston and the backplate, is splined to the converter turbine. The lockup clutch is
engaged and released in response to electronic signals from the TCM. Lockup clutch
engagement provides a direct drive from the engine to the transmission gearing. This
eliminates converter slippage and provides maximum fuel economy and vehicle
speed. The torsional damper absorbs engine torsional vibration to prevent
transmission through the powertrain.

The lockup clutch releases at lower speeds or when the TCM detects conditions
requiring it to be released.

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7
Typical 3000 product family

8
Typical 4000 product famliyHD 4060P

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1.5 PLANETARY GEARS AND CLUTCHES

A series of three helical planetary gear sets and shafts provides the mechanical gear
ratios and direction of travel for the vehicle. The planetary gear
sets are controlled by five multiplate clutches that work in pairs to
produce maximum six forward speeds and one reverse speed.The clutches are
applied and released hydraulically in response to electronic signals from the TCM to
the appropriate solenoids.

1.6 COOLER CIRCUIT

The transmission fluid is cooled by an integral (transmission-mounted) or remote-

mounted oil cooler. Connections to the cooling circuit are located at the front or rear
of the transmission to facilitate installation of remote cooler lines. On shallow sump
models, only rear ports are available. On retarder models, only rear cooler ports may
be used. The integral cooler is located on the lower rear portion of the transmission,
replacing the remote cooler manifold. Integral cooler oil ports are internal requiring
only coolant to be routed to and from the cooler.

A new feature has been added on all retarder-equipped transmissions. Modification

of the retarder housing allows the addition of either a remote or integral cooler for
transmission sump fluid in addition to retarder out fluid. A cover is placed over the
sump cooling ports when the provision is not used. The sump cooler ports are
located on the lower right rear face of the retarder housing

1.7 RETARDER (If present)

The self-contained retarder is at the output of the transmission and consists of a

vaned rotor which rotates in a vaned cavity. The rotor is splined to and driven by the
output shaft. An external accumulator holds transmission fluid until the retarder is
activated. When the retarder is activated, the fluid in the accumulator is pressurized
by the vehicle air system and directed into the retarder cavity. The interaction of the
fluid with the rotating and stationary vanes causes the retarder rotor speed, and
hence the output shaft, to decrease and slow the vehicle or to limit speed on a
downhill grade.

When the retarder is deactivated, the retarder cavity is evacuated and the
accumulator is recharged with fluid.

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2 SHIFT SELECTOR

DIGITAL DISPLAY*

MODE ID
MODE INDICATOR (LED)

Push simultaneously to enter

diagnostic mode and fluid level
check

* NOTE: The first number displayed is highest forward range available and
second number is range attained in selected position. Visually check to
confirm range selected. If display is flashing, shift is inhibited.

2.1 INTRODUCTION

Vehicle manufacturers may choose different types of shift selectors for their vehicles.
The shift selector in your Allison-equipped vehicle will be similar to the pushbutton
style shown above.

With an Allison-equipped vehicle, it is not necessary to select the right moment to

upshift or downshift during changing road and traffic conditions. The Allison 3000 and
4000 product families transmissions
does it for you. However, knowledge of the shift selector positions, ranges available,
and when to select them, will make vehicle control and your job even easier. It is
recommended to select lower ranges when descending long grades

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(with and without retarder) to reduce wear on service brakes. Be sure to read
RANGE SELECTION.

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2.2 PUSHBUTTON SHIFT SELECTOR (With digital display)

General Description. The pushbutton shift selector has R, N, D, , , a MODE

button, and a digital display.

R Pushbutton. Press this button to select Reverse.

N Pushbutton. Press this button to select Neutral.

D Pushbutton. Press this button to select Drive. The highest forward range available
will appear in the digital display window. The transmission will start out in the lowest
available forward range and advance automatically to the highest range.

, (Arrow) Buttons. When a lower range is desired, after D (Drive) has been
pressed, press the (Down) arrow button until the desired range is shown in the
display window. Likewise, if the transmission is held in a low range by the
(Down) arrow, press the (Up) arrow to request the next higher range.
Continuous pressing of either the (Up) or (Down) arrow buttons will request the
highest or lowest range available.

Access fluid level data and diagnostic codes with the pushbutton selector by pressing
the (Up) and (Down) arrow buttons at the same time.

NOTE: Fluid level information is displayed (if optional oil level sensor
is present) after the first simultaneous press. Press both buttons again to
obtain diagnostic data.

MODE Button. The MODE button may allow the driver to enable a secondary shift
schedule or other special function that has been previously programmed into the
electronic control unit at the request of the OEM. For example, the OEM for a motor
home may have provided a secondary shift schedule for improved fuel economy.
The name of the special function (ECONOMY) should appear on the MODE ID label
adjacent to the MODE button. Pressing the MODE button activates the
ECONOMY shift schedule and illuminates the MODE INDICATOR (LED). Other
special functions which may be activated by the MODE button are D1 selection or
PTO enable. The MODE button is also used to view diagnostic code information.
After viewing the first diagnostic code which appears in the digital display, press the
MODE button to view the 2nd diagnostic code logged. Repeat this procedure to
view the 3rd, 4th, and 5th code positions. The code displayed is active when the
MODE INDICATOR (LED) is illuminated.

Digital Display. During normal operation, when D (Drive) is selected, the digital
display shows the highest forward range attainable for the shift schedule in use.

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 2.2.1 RANGE SELECTION Reverse

PUSHBUTTONSELECTOR

WARNING: 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
Ensure that the engine is at low idle rpm (below 1000)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.

WARNING: R (Reverse) may not be obtained due to an active

inhibitor. Always apply the service brakes when selecting
R (Reverse) because a service brake inhibit may be present. When
the R is flashing, it indicates that the shift to R (Reverse) is
inhibited. Check for active diagnostic codes if R (Reverse) is not
obtained

CAUTION: Do not idle in R (Reverse) for more than five minutes.

Extended idling in R (Reverse) may cause transmission
overheating and damage. Always select N (Neutral) whenever time
at idle exceeds five minutes.

NOTE: Visually check the digital display window whenever a button is

pushed or the lever is moved to be sure that the range selected is shown
(i.e., if the N (Neutral) button is pressed, N should appear in the digital
display). A flashing display indicates that the range selected was not
attained
due to an active inhibit.

Completely stop the vehicle and let the engine return to idle before shifting
from a forward range to Reverse or from Reverse to a forward range.
The digital display will display R when Reverse is selected.

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 2.2.2 RANGE SELECTION Neutral

PUSHBUTTONSELECTOR

WARNING: When starting the engine, make sure the service

brakes are applied. Failure to apply the service brakes may result in
unexpected vehicle movement.

WARNING: Vehicle service brakes, parking brake, or emergency

brake must be applied whenever N (Neutral) is selected to prevent
unexpected vehicle movement. Selecting N (Neutral) does not
apply vehicle brakes, unless an auxiliary system to apply the
parking brake is installed (see Operators Manual for the vehicle).

WARNING: If you let the vehicle coast in N (Neutral), there is no

engine braking and you could lose control. Coasting can also cause
severe transmission damage. To help avoid injury and property
damage, do not allow the vehicle to coast in N (Neutral).

Use Neutral when you start the engine, to check vehicle accessories, and
for extended periods of engine idle operation (longer than five minutes).
For vehicles equipped with the pushbutton selector, Neutral is selected by
the TCM at startup. For vehicles equipped with the lever selector, the
vehicle will not start unless Neutral has been selected. If the vehicle starts
in any range other than Neutral, seek service immediately. Neutral is also
used during stationary operation of the power takeoff (if your vehicle is
equipped with a PTO). The digital display will show N when Neutral is selected.
Always select N (Neutral) before turning off the vehicle engine.

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 2.2.3 RANGE SELECTION Drive

PUSHBUTTONSELECTOR

WARNING: D (Drive) may not be obtained due to an active inhibitor.

Always apply the service brakes when selecting D (Drive)
because a service brake inhibit may be present. When the D is
flashing, it indicates that the shift to D (Drive) is inhibited. Check for active
diagnostic codes if D (Drive) is not obtained.

CAUTION: Do not idle in D (Drive) for more than five minutes.

Extended idling in D (Drive) may cause transmission overheating and
damage. Always select N (Neutral) if time at idle is longer than five
minutes.

NOTE: Turn off the vehicle HIGH IDLE switch, if present, before shifting
from N (Neutral) to D (Drive) or R (Reverse). D (Drive) or R (Reverse)
will not be attained unless the shift is made with the engine at idle. Also,
be aware of other interlocks that would prevent obtaining D (Drive) or R
(Reverse). Examples are wheelchair lift not stored and service brakes
not applied (service brake interlock present).

The transmission will initially attain first range when D (Drive) is selected
(except for those units programmed to start in second range). As vehicle
speed increases, the transmission will upshift automatically through each
range. As the vehicle slows, the transmission will downshift automatically.
The digital display will show the highest range available in D (Drive).

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 2.2.4 RANGE SELECTION 1-6

PUSHBUTTONSELECTOR

WARNING: If you just downshift or just use service brakes when going
downhill, you can lose control and cause injury and property damage. To
help avoid loss of control, use a combination of
downshifting, braking, and other retarding devices. Downshifting
to a lower transmission range increases engine braking and helps
you to maintain control. The transmission has a feature to prevent
automatic upshifting above the lower range selected. However,
during downhill operation, if engine governed speed is exceeded in the
lower range, the transmission may upshift to the next higher range. This
will reduce braking and could cause a loss of control.
Apply the vehicle brakes or other retarding device to prevent
exceeding engine governed speed in the lower range selected.

Occasionally, road conditions, load, or traffic conditions will make it

desirable to restrict automatic shifting to a lower range. Lower ranges
provide greater engine braking for going down grades (the lower the range, the
greater the braking effect).

The pushbutton selector utilizes arrow buttons to select individual forward ranges.
Push the (Up) or (Down) arrow to the desired range. The
digital display will show your choice of range. Even though a lower range was
selected, the transmission may not downshift until vehicle speed is
reduced (this prevents excessive engine speed in the lower range).

* Actual ranges available depend on programming by vehicle manufacturer

Use this range (1) when pulling through mud and deep snow, when
maneuvering in tight spaces, or while driving up or down grades. First
range provides the vehicle with its maximum driving torque and maximum
engine braking effect. For vehicles equipped with the pushbutton selector, push the
(Down) arrow until first range appears in the select window.

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18
3 DRIVING TIPS

3.1 CHECK TRANS LIGHT

The electronic control system is programmed to inform the operator of a

problem with the transmission system and automatically take action to
protect the operator, vehicle, and transmission. When the Transmission
Control Module (TCM) detects a problem condition, the TCM restricts
shifting, turns on the CHECK TRANS light on the instrument panel, and
registers a diagnostic code.

NOTE: For some problems, diagnostic codes may be registered without

the TCM activating the CHECK TRANS light. Your Allison
Transmission authorized service outlet should be consulted whenever
there is a transmission-related concern. They have the equipment to
check for diagnostic codes and to correct problems which arise.

Each time the engine is started, the CHECK TRANS light will illuminate, then turn off
after a few seconds. This momentary lighting is to show that the status light circuits
are working properly. If the CHECK TRANS light does not illuminate
during ignition, or if the light remains on after ignition, the system should be checked
immediately.

Continued illumination of the CHECK TRANS light during vehicle operation (other
than start-up) indicates that the TCM has signaled a diagnostic code. Illumination of
the CHECK TRANS light is accompanied by a flashing display from the shift selector.
The shift selector display will show the actual range attained and the
transmission will not respond to shift selector requests.

The indications from the shift selector are provided to inform the operator that the
transmission is not performing as designed and is operating in the limp home mode
with reduced capabilities. Before turning the ignition off, the transmission may be
operated for a short time in the selected range in order to limp home for service
assistance. Service should be performed immediately in order to minimize the
potential for
damage to the transmission.

When the CHECK TRANS light comes on and the ignition switch is turned off, the
transmission will remain in N (Neutral) until the condition causing the CHECK
TRANS light is corrected.

Generally, while the CHECK TRANS light is on, upshifts and downshifts will be
restricted and direction changes will not occur. Lever and pushbutton shift
selectors do not respond to any operator shift requests while the CHECK TRANS
light is illuminated. The lockup clutch is disengaged when transmission shifting is
restricted or during any critical transmission malfunction.

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3.2 DIAGNOSTIC CODES

Diagnostic codes are numerical indications relating to a malfunction in transmission

operation. These codes are logged in a list in the TCM memory with the most severe
or
otherwise most recent code listed first. A maximum of five codes (numbered d1d5)
may be listed in memory at one time. As codes are added, the oldest nonactive code
is dropped from the list. If all codes are active, the code with the lowest priority that is
not included on the severity list is dropped from the list. Access to the diagnostic
codes and code information is through the pushbutton and lever shift selectors, or
using an Allison DOC diagnostic tool.

The TCM separately stores the active and historical (nonactive) codes. An active
code is any code that is current in the TCM decision-making process. Historical
codes are codes that are retained in the TCMs memory and will not necessarily
affect the TCM decision-making process. Historical codes are useful in determining
if a problem is isolated, is intermittent, or results from a previous malfunction.
When the diagnostic mode is entered, the first code (position d1) is displayed as fs
Follows: Example code P0722
Displayed as: d1, P, 07, 22
Press the MODE button momentarily to display codes for positions d2d5 in the
same manner. After a fixed number of ignition cycles, a code may be deleted
from memory if it has not recurred. The shift selector diagnostic mode will end
automatically after two minutes without operator input.

3.3 DIAGNOSTIC CODE DISPLAY PROCEDURE

Diagnostic codes can be read and cleared by two methods:

With the Allison DOC Diagnostic tool. The use of the

Allison DOC diagnostic tool is described in the instruction
manual furnished with each tool.
With the pushbutton selector.

Pushbutton Shift Selector

To Begin the Diagnostic Process:

Bring the vehicle to a stop at a safe location.

Apply the parking brake.

To Display Stored Codes:

Simultaneously press the (Up) and (Down) arrow buttons once to access
the diagnostic display mode press the buttons twice if a transmission oil
level sensor is installed.
Observe the digital display for codes (codes will appear two digit at a time).

20
 Press the MODE button to see the next code repeat for subsequent codes.

21
 NOTE: Be sure to record all codes displayed before they are cleared.
This is essential for troubleshooting.

To Clear Active Indicators and Resume Vehicle Operation:

Press and hold the MODE button for approximately 10 seconds until the mode
indicator (LED) flashes. Release the MODE button and active indicators such as the
CHECK TRANS light will not be illuminated. Some codes are self-clearing and
others require ignition cycles to clear.

3.4 ACCELERATOR CONTROL

WARNING: To help avoid injury or property damage caused by

sudden movement of the vehicle, do not make shifts from N (Neutral)
to D (Drive) or R (Reverse) when the throttle pedal is depressed. If
you shift while the throttle is depressed too far, the transmission will
only engage if the throttle pedal is released in the next three seconds.
This may cause a sudden movement of the vehicle. Leaving the
throttle pedal depressed longer than three seconds causes the
transmission to remain in N (Neutral). Avoid this condition by making
shifts from N (Neutral) to D (Drive) or R (Reverse) only when the
throttle is closed.

The position of the accelerator pedal influences the timing at which automatic shifting
occurs. When the pedal is fully depressed, upshifts will occur automatically at high
engine speeds. A partially depressed position of the pedal will cause the
upshifts to occur at lower engine speeds. An electronic throttle position signal tells
the TCM how much the operator has depressed the pedal. Excessive throttle position
affects directional change shifts (shifts from N (Neutral) to D (Drive) or R (Reverse).

3.5 DOWNSHIFT AND DIRECTION CHANGE INHIBITOR FEATURE

NOTE: Turn off the vehicle HIGH IDLE switch, if present, before
shifting from N (Neutral) to D (Drive) or R (Reverse). The shift from
N (Neutral) to D (Drive) or R (Reverse) is inhibited when engine speed
is above idle.

There is no speed limitation on upshifting, but there is a limitation on downshifting

and for shifts
which cause a direction change such as D (Drive) to R (Reverse) or R (Reverse) to
D (Drive).

22
Manual range downshifts will not occur until a programmed value of output speed is
reached. When a range downshift is manually selected and the transmission output
speed is above the programmed value of the selected range, the transmission will
stay in the range it was in even though a lower range was requested. Apply the
vehicle service brakes or a retarding device to reduce the transmission output speed
to the programmed value so the shift to the lower range will occur.

Directional shifts, D (Drive) to R (Reverse) or R (Reverse) to D (Drive), will not

occur if selected when throttle position, engine speed, or transmission output speed
is above the calibration limit for a calibration time period. The current calibration time
period for engine speed is 0.5 second and for throttle position and output speed is
three seconds.

Shifts from N (Neutral) to D (Drive) or R (Reverse) are also inhibited when the
TCM has been programmed (by input/output function) to detect that auxiliary
equipment is in operation and the shift should not be allowed.

When a directional shift is inhibited, the TCM will put the transmission in
N (Neutral) and the digital display, if present, will flash the letter of the range
selected (D or R). Reselect D (Drive) or R (Reverse) when engine throttle, engine
speed, and transmission output speed are below the calibration value. With a
pushbutton selector, just depress the desired pushbutton again.

When a direction change shift is requested and the engine throttle, engine speed,
and transmission output speed drop below the calibration value during the calibration
time interval, the shift to D (Drive) or R (Reverse) will occur. For example, if the
transmission output speed was just above the calibration limit when R (Reverse) was
selected, but dropped below the limit during the next three seconds, the shift to
R (Reverse) would occur (assuming the engine was at idle and throttle was closed).

3.6 USING THE ENGINE TO SLOW THE VEHICLE

WARNING: If you just downshift or just use service brakes when going
downhill, you can lose control and cause injury and property damage. To
help avoid loss of control, use a combination of
downshifting, braking, and other retarding devices. Downshifting to a
lower transmission range increases engine braking and helps you to
maintain control.
The transmission has a feature to prevent automatic upshifting above the
lower range selected. However, during downhill operation, if
engine governed speed is exceeded in the lower range, the
transmission may upshift to the next higher range. This will reduce braking
and could cause a loss of control. Apply the vehicle brakes or
other retarding device to prevent exceeding engine governed speed in the
lower range selected.

23
To use the engine as a braking force, select the next lower range. If the vehicle is
exceeding the maximum speed for this range, use the service brakes and/or retarder
to slow the vehicle. When a lower speed is reached, the TCM will automatically
downshift the transmission.

Engine braking provides good speed control for going down grades. When the
vehicle is heavily loaded, or the grade is steep, it may be desirable to preselect a
lower range before reaching the grade. If engine-governed speed is exceeded, the
transmission will upshift automatically to the next range.

3.7 USING THE HYDRAULIC RETARDER (If present)

WARNINGS: DO NOT USE THE RETARDER DURING

INCLEMENT WEATHER OR WHEN ROAD SURFACES ARE
SLIPPERY. De-energize the retarder at the master control switch.
To help avoid injury or property damage caused by loss of vehicle
control, be ready to apply vehicle brakes or other retarding device if the
transmission retarder does not apply. If a retarder is present but is not
detected by autodetect, the retarder will not function. Be sure to check
for proper retarder function periodically. Whenever the retarder does not
apply, seek service help immediately.

On vehicles which have the primary retarder control based upon

closed throttle position, brake pedal position, or brake apply pressure,
always manually disable the retarder controls during inclement
weather or slippery road conditions.
Regardless of the type of Allison retarder controls on your vehicle, the following
safety features are common to each configuration:

The retarder can be disabled when inclement weather or slippery road

conditions are present.
Vehicle brake lights should always be on when the retarder is applied
(periodically verify that they are working).
Anti-lock brake systems send a signal to the transmission TCM to indicate that the
brake system is activated.

NOTE: The retarder is automatically disabled (and the lockup clutch is

disengaged) whenever the vehicle ABS (anti-lock brake system) is active.
However, in case the ABS system malfunctions, it is
recommended that the retarder enable switch, if present, be disabled.

A hydraulic retarder is available on all of the models series covered in this manual.
The retarder is activated and controlled in various ways. The control depends upon
the vehicle type and particular duty cycle. Both manual and automatic controls are
available. Automatic controls are applied by the TCM. In Allison 4th Generation
Control Systems, the TCM may also activate or limit retarder operation in responce to
torque speed control or electronic retarder control messages received on the

24
vehicles J1939 Data Link. Some types of controls and the amount of retarder
application are shown in the Types of Retarder Control table that follows.
The presence of a retarder must be autodetected as part of the Allison 4th
Generation Ccontrols system.

NOTE: If your transmission has a retarder but it is not functioning, it may

not have been autodetected during vehicle manufacture. Go
immediately to your nearest Allison Transmission service outlet to have
autodetect reset or the retarder enabled using Allison DOC for PC-
service tool .

NOTE: When reduced retarder performance is observed, be sure that the

transmission fluid level is within the operating band on the dipstick.
Low fluid level is a common cause for retarder performance complaints.

NOTE: The retarder requires about one second to reach full capacity
requested. Be sure to anticipate this delay when using the retarder.
Anticipation will prevent unnecessary service brake applications during
non-emergency stops.

Type Description Amount of Application

Automatic Automatic Auto Full On * Full On when closed throttle
sensed

Brake Pressure Single pressure switch Off or Full On (based on brake

Apply ** pressure)

Three pressure switches 1 / 3, 2 / 3, or Full On (based

on brake pressure)

Pedal Position ** Special brake pedal 1 / 3, 2 / 3, or Full On (based

on pedal position)

J1939 Data Link Digital message from engine Zero to Full apply
controller

Combinations of the Auto half-on plus pressure Half capacity at closed throttle or
above systems ** switch* Full On with brake pressure

Auto 1/3 on plus two pressure 1 / 3, capacity at closed throttle

switches * or 2 / 3 and Full On with brake
pressure

Foot pedal plus pressure switch Full modulation with separate

pedal, or Full On with brake
pressure

Table 1. Types of Retarder Control

25
26
 NOTE: * These control systems may apply the retarder at high speed on
grades when the vehicle has road speed limiting and the retarder is
enabled.
** For retarder apply systems integrated with the service brake system,
the retarder is most effective when applied with light brake pedal
pressure for 12 seconds to allow the retarder to fully charge. Added pedal
pressure can be applied when more aggressive braking is desired.

NOTE: When the transmission fluid or engine water temperature

(engine water is an OEM option) exceeds programmed limits, retarder
capacity is gradually reduced automatically to minimize or avoid
possible system overheating.

Contact your vehicle manufacturer to understand how the retarder controls have
been integrated into your vehicle.

CAUTION: Observe the following cautions when driving a vehicle

equipped with a retarder.
THE RETARDER WORKS ONLY WHEN THE ENGINE IS AT
CLOSED THROTTLE.
OBSERVE TRANSMISSION AND ENGINE TEMPERATURE
LIMITS AT ALL TIMES. Select the lowest possible transmission
range to increase the cooling system capacity and total retardation
available.
In the event of OVERHEATING, DECREASE THE USE OF THE
RETARDER; USE THE SERVICE BRAKES TO SLOW THE
VEHICLE.
OBSERVE THE RETARDER/SUMP OVERTEMP LIGHT to
ensure that it responds properly to retarder temperature.

NOTE: Transmission oil level must be set correctly for highest retarder
effectiveness. As much as 2 liters (2 quarts) too high or too low can
reduce retarder effectiveness and increase transmission temperature.

3.8 RANGE PRESELECTION

Range preselection means selecting a lower range to match the driving conditions
you encounter or expect to encounter. Learning to take advantage of preselected
shifts will give you better control on slick or icy roads and down grades.

Downshifting to a lower range increases engine braking. The selection of a lower

range often prevents cycling between that range and the next higher range on a
series of short up-and-down hills.

NOTE: Preselecting during normal operation may result in reduced

fuel economy.

27
3.9 COLD WEATHER STARTS

All 3000 and 4000 product families transmissions are programmed to restrict full
operation
until specific temperatures are reached. Refer to the following chart for temperature
restrictions.

Sump Oil Temperature CHECK Operation

TRANS Light
32C (25F) to 7C (19F) OFF Neutral, Reverse, Second
7C (19F) * OFF Full operation in all ranges

NOTE: When sump temperature is below 10C (50F), and

transmission fluid is C-4 (not DEXRON or TranSynd), follow this
procedure when making directional change shifts:

To shift from forward to reverse; select N (Neutral) and then

R (Reverse).
To shift from reverse to forward; select N (Neutral) and then
D (Drive), or other forward range.

Failure to follow this procedure may cause illumination of the CHECK

TRANS light and then transmission operation will be restricted to N
(Neutral). Transmission operation at cold ambient temperatures may
require preheating or the use of a lower viscosity transmission fluid.

3.10 DRIVING ON SNOW OR ICE

WARNING: Using the retarder on wet or slippery roads may cause loss of
traction on the drive wheels your vehicle may slide out of control. To help
avoid injury or property damage, turn the retarder
enable to OFF when driving on wet or slippery roads.

NOTE: The retarder is automatically disabled whenever the vehicles

ABS (antilock brake system) is active. However, in case the ABS
system malfunctions, it is recommended that the retarder enable switch, if
present, be disabled.

If possible, reduce the vehicle speed and select a lower range before traction is lost.
Select the range that will not exceed the speed you expect to maintain.

Accelerate or decelerate very gradually to prevent loss of traction. It is very important

to reduce speed gradually when a lower range is selected. It is important
that you reach the lower range selected before attempting to accelerate. This will
avoid an unexpected downshift during acceleration.

28
3.11 ROCKING OUT

WARNING: To help avoid injury or property damage caused by

sudden movement of the vehicle, do not make shifts from N (Neutral) to D
(Drive) or R (Reverse) when the throttle pedal is depressed. If
you shift while the throttle is depressed too much, the transmission
will only engage if the throttle is released in the next three seconds.
That can cause a sudden movement of the vehicle. Leaving the
throttle open longer than three seconds causes the transmission to
remain in N (Neutral). Avoid this condition by making shifts from N
(Neutral) to D (Drive) or R (Reverse) only when the throttle is closed.

CAUTION: DO NOT make N (Neutral)-to-D (Drive) or directional shift

changes when the engine rpm is above idle. Also, if the wheels
are stuck and not turning, do not apply full power for more than 30
seconds in either D (Drive) or R (Reverse). Full power for more than
30 seconds under these conditions will cause the transmission to
overheat. If the transmission overheats, shift to N (Neutral) and operate
the engine at 12001500 rpm until it cools (23 minutes).

If the vehicle is stuck in deep sand, snow, or mud, it may be possible to rock it out.
Shift to D (Drive) and apply steady, light throttle (never full throttle). When the
vehicle has rocked forward as far as it will go, apply and hold the vehicle service
brakes. Allow the engine to return to idle; then select R (Reverse). Release the
brakes and apply a steady, light throttle and allow the vehicle to rock in R (Reverse)
as far as it will go. Again, apply and hold the service brakes and allow the engine to
return to idle. This procedure may be repeated in D (Drive) and R (Reverse) if each
directional shift continues to move the vehicle a greater distance. Never make N
(Neutral)-to-D (Drive) or directional shift changes when the engine rpm is above idle.

3.12 HIGH FLUID TEMPERATURE

The transmission is considered to be overheated when any of the following

temperatures are exceeded:

Sump fluid 121C (250F)

Fluid to cooler 149C (300F)
Retarder out fluid 165C (330F)

If the transmission overheats during normal operations, check the fluid level in the
transmission.

If the engine temperature gauge indicates a high temperature, the transmission is

probably overheated. Stop the vehicle and check the cooling system. If it appears to
be functioning properly, run the engine at 12001500 rpm with the transmission in N

29
(Neutral). This should reduce the transmission and engine temperatures to normal
operating levels in 2 or 3 minutes. If temperatures do not decrease, reduce the
engine rpm.

CAUTION: The engine should never be operated for more than 10

seconds at full throttle with the transmission in range and the output
stalled. Prolonged operation of this type will cause the transmission
fluid temperature to become excessively high and will result in severe
overheat damage to the transmission.

If the engine temperature indicates a high temperature, an engine or radiator problem

is indicated. If high temperature in either the engine or transmission
persists, stop the engine and have the overheating condition investigated by
maintenance personnel.

3.13 PARKING BRAKE

WARNING: Take the following precautions so that unexpected,

possible sudden vehicle movement is avoided. Whenever it becomes
necessary to leave the vehicle, even momentarily, while the engine is
in operation, place the transmission shift selector in N (Neutral) (or
for special pumping operations, disconnect drive to the wheels), set the
parking brake and/or emergency brakes, and chock the wheels.

The parking brake is only intended to secure an unattended vehicle with the engine
ignition OFF. Always maintain the vehicle parking brake system according to the
manufacturers specifications. The parking brake may not have sufficient capacity to
restrain a vehicle with the engine running and the transmission in a forward or
reverse range. As indicated in the above WARNING, when the vehicle is unattended
and the engine is in operation, the transmission must be in N (Neutral) (or for
special pumping operations, drive to the wheels disconnected) with the brakes fully
applied and the wheels chocked.

30
3.14 TOWING OR PUSHING

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

The engine cannot be started by pushing or towing. Before pushing or towing do one
of the following:

Disconnect the driveline

Lift the drive wheels off the road
Remove the axle shafts from the drive wheels.

Be sure to cover the wheel openings to prevent loss of lubricant and entry of dust
and dirt if the axel shafts are removed. An auxiliary air supply will usually be
required to actuate the vehicle brake system.

3.15 CRUISE CONTROL OPERATION (If present)

Operating an Allison 4th generation controls- equipped vehicle on cruise control may
cause the
transmission to shift cycle if the cruise control is set close to a scheduled shift point.
One of the following actions may eliminate shift cycling:

Select a different shift schedule by pushing the MODE button on the shift selector.
Select a lower range by pushing the (Down) arrow
Change the cruise control speed setting away from the shift point.

The engine brake on some vehicles equipped with an Allison 3000 and 4000 product
families transmission may be controlled by the transmission TCM. With this
configuration,
the transmission will automatically select a lower range when the engine brake is
applied or the throttle is near idle position.

Operating a vehicle in cruise control with engine brake turned-on, controlled by the
transmission TCM, may cause unwanted application of the engine brake when the
cruise control decelerates for downhill grades. Operator may choose to turn off cruise
control to eliminate unwanted condition.

3.16 TURNING OFF THE VEHICLE

Note: Always select N (Neutral) prior to turning off the vehicle engine.

31
4 POWER TAKEOFF OPERATION

4.1 ENGINE-DRIVEN POWER TAKEOFF (PTO)

CAUTION: Do not exceed the engagement and operational speed

limits imposed on the driven equipment during the operation of the
PTO.

If a PTO is present, it will normally be mounted on either the left or right side of
3000 product family, transmissions. There is also an option to have the PTO mounted
on the left side or top of the transmission. On 4000 product family transmissions, the
PTO will be
located on the left side or on the top of the transmission. The PTO drive gear is
engine-driven and therefore provides direct engine power. The PTO can be operated
when the vehicle is either moving or stopped.
The PTO gear is in constant mesh with the drive gear in the converter housing.
However, the PTO may either be constant drive (output always powered) or clutched
driven. When the PTO is clutch driven, the clutch is part of the PTO not the
transmission. A clutch drive PTO is powered only when the PTO clutch is engaged.
Be sure that the limits for PTO engagement speed and operational speed are not
exceeded. Consult the vehicle manufacturers literature for these speed limits. Also,
all 3000 and 4000 product famliy transmission, equipped vehicles with PTO enable
have engagement and
operational speed limits programmed into the TCM to help protect PTO equipment.
Some speed limits have default values which are programmed out of the operating
range and will need to be set for your particular PTO duty cycle. Consult your
vehicle manufacturer to see if your transmission has been programmed and what
operational limits have been established.
When the programmed engagement speed is exceeded, the PTO will not engage.
The PTO engagement must be retried after the speed has been reduced. When
operational speeds (either engine or transmission output) are exceeded, the PTO
will
deactivate and the PTO engagement process must be repeated.

32
5 CARE AND MAINTENANCE

5.1 PERIODIC INSPECTIONS

The Allison 3000 and 4000 product families, Series transmissions require
minimum maintenance. Careful attention to the fluid level
and the connections for the electronic and hydraulic circuits is very
important.

Do the following periodic inspection:

Keep the transmission clean for easier inspection.

Make periodic checks for loose bolts and fluid leaks around fittings, lines, and
transmission openings.
Check the condition of the electrical wiring harnesses regularly
Check the engine cooling system occasionally for evidence of transmission
fluid that would indicate a faulty oil cooler.
Report any abnormal condition to your maintenance personnel.

5.2 PREVENT MAJOR PROBLEMS

Help Allison 4th generation controls oversee the operation of the transmission. Minor
problems can be kept from becoming major problems if you notify an Allison
Transmission distributor or dealer when one of these conditions occur:

Shifting feels odd

Transmission leaks fluid
Unusual transmission-related sounds

NOTE: Changes in sound caused by normal engine thermostatic fan

cycling, while climbing a long grade with a heavy load, may be mistaken
for transmission-related sounds.

CHECK TRANS light comes on frequently

33
34
5.3 IMPORTANCE OF PROPER FLUID LEVEL

It is important that proper fluid level be maintained at all times because the
transmission fluid cools, lubricates, and transmits hydraulic power. If the fluid level is
too low, the converter and clutches do not receive an adequate supply of fluid. If
fluid level is too high, the fluid can aerate. Aerated fluid can cause the transmission
to shift erratically or overheat.

The 3000 and 4000 product families transmissions have an optional oil level sensor
(OLS)
that allows the operator to obtain an indication of fluid level from the shift selector.
However, no oil level sensor diagnostics take place unless the OLS is
autodetected by the 4th generation controls. Frequently check for the presence
of oil level diagnostics if the transmission is known to contain an OLS. If an OLS is
not detected during a fixed number of starts, the WTEC IIIAllison 4th generation
controls system concludes that no
OLS is present. If an OLS is known to be present, but has not been detected, then
troubleshooting of the OLS circuit is required. After the OLS circuit is repaired,
reset autodetect or manually select the OLS function using theAllison DOC for
PC-service tool.
(Refer to the Troubleshooting Manual for detailed troubleshooting procedures.)

NOTE: To correctly check the transmission fluid level using the

dipstick, the transmission fluid must be at operating temperature. The
oil level sensor method of checking the fluid level compensates for
transmission fluid temperature between 60C104C (140F220F).
Any temperature below 60C (140F) or above 104C (220F) will result in
an Invalid for Display condition.

35
5.4 FLUID LEVEL CHECK USING THE PUSHBUTTON

DIGITAL DISPLAY*

MODE ID
MODE INDICATOR (LED)

Push simultaneously to enter

diagnostic mode and fluid level
check

The transmission must be equipped with the optional oil level sensor to be able to
read fluid level information.

NOTE: The pushbutton selector can display two characters at one time

Park the vehicle on a level surface, shift to N (Neutral), and apply the parking
brake.
Pushbutton shift selector If equipped with an oil level sensor,
simultaneously press the(Up) and (Down) arrow buttons.

NOTE: The fluid level check may be delayed until the following
conditions are met:

The fluid temperature is above 60C (140F) and below 104C (220F).
The transmission is in N (Neutral).
The engine is at idle.
The transmission output shaft is stopped. (The vehicle has been
stationary fo r approximately two minutes to allow the fluid to settle).

A delayed fluid level check for Allison 4th generation controls is indicated by a
flashing display under SELECT and a digit countdown from 8 to 1 under MONITOR.

36
 Correct Fluid Level o,L is displayed (o,L represents Fluid (Oil)
Level Check Mode), followed by o,K. The o,K display indicates the
fluid is within the correct fluid level zone. The sensor display and the
transmission dipstick may not agree exactly because the oil level sensor
compensates for fluid temperature.

NOTE: Fluid level diagnostic displays occur one character at a time.

Low Fluid Level o,L is displayed (o,L represents Fluid (Oil)

Level Check Mode), followed by Lo (Lo represents Low Oil
Level) and the number of quarts the transmission fluid is low.
Example: o L L o 0 2
2 indicates 2 additional quarts of fluid will bring the fluid level
within the middle of the oK zone.
High Fluid Level o,L is displayed (o,L represents Fluid (Oil)
Level Check Mode), followed by HI (HI represents High Oil
Level) and the number of quarts the transmission is overfilled.
Example: o L H I 0 1
1 indicates 1 quart of fluid above the full transmission level.

Invalid for Display o,L is displayed (o,L represents Fluid (Oil)

Level Check Mode), followed by - - and a numerical display. The
numerical display is a fault code and indicates conditions are not proper to
receive the fluid level information, or that there is a system malfunction.
The fault codes that may be encountered are shown in Table 2.

Display Cause of Code

o,L, - -, 0, X Settling time too short
o,L, - -, 5, 0 Engine speed (rpm) too low
o,L, - -, 5, 9 Engine speed (rpm) too high
o,L, - -, 6, 5 Neutral must be selected
o,L, - -, 7, 0 Sump fluid temperature too low
o,L, - -, 7, 9 Sump fluid temperature too high
o,L, - -, 8, 9 Output shaft rotation
o,L, - -, 9, 5 Sensor failure*
* Report sensor failure display to a distributor or dealer in your area.
Table 2. Oil Level Fault Codes

CAUTION: Low or high fluid level can cause overheating and

irregular shift patterns. These conditions can damage the transmission
if not corrected.

NOTE: To exit the fluid level display mode, press any range button on

the pushbutton shift selector.

37
 5.5 MANUAL FLUID CHECK PROCEDURE

WARNING: 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
have completed all of the following procedures:

Put the transmission in N (Neutral)

Ensure that the engine is at low idle (500800 rpm)
Apply the parking brake and emergency brakes and make sure
they are properly engaged
Chock the wheels and take any other steps necessary to keep the
vehicle from moving.

Clean around the end of the fill tube before removing the dipstick.
This will aid in preventing dirt or foreign matter from entering the
hydraulic system, which can cause valves to stick, undue wear of
transmission parts, or clogged passages. Check the fluid level by the
following procedure and report any abnormal level to your maintenance
personnel.

38
 5.5.1 COLD CHECK

The Cold Check determines if the transmission has enough fluid to be operated
safely until a Hot Check can be made.

NOTE: The correct fluid level can not be determinded unless the
transmission is in a level position.

CAUTION: DO NOT start the engine until the presence of sufficient

transmission fluid has been confirmed. Remove the transmission fluid
dipstick and be sure that the static fluid level is near the HOT FULL
mark.

CAUTION: The fluid level rises as fluid temperature rises. DO NOT fill the
transmission above the COLD CHECK band if the tranmission fluid is
below normal operating temperatures. During operation, an overfull
transmission can be become overheated, leading to transmission damage.

A cold check may be made when the fluid 1649C (60120F). Before the
engine is started, pull the transmission dipstick and confirm that the transmission
fluid level is near the HOT RUN mark.

To perform a COLD CHECK, do the following:

Start the engine and run it at idle (500800 rpm) in N (Neutral) for about one
minute.
Move the vehicle to a level surface, put transmission in N (Neutral), and set the
parking brake.
With engine idling (500800 rpm), shift to D (Drive) and then to R (Reverse) to
clear air from the hydraulic circuits.
Shift to N (Neutral) and leave engine at idle.
Remove the dipstick and wipe clean. Reinsert the dipstick into the transmission.
Remove the dipstick and check the fluid level. If the fluid on the dipstick is within
the COLD RUN band, the level is satisfactory. If the fluid level is not within this
band, add or drain fluid as necessary to bring the level within the COLD RUN
band.
Perform a Hot Check at the first opportunity after normal operating temperature
(7193C; 160200F) is reached.

CAUTION: The transmission must not be operated for extended

periods of time until a Hot Check has verified proper fluid level.
Transmission damage can result from extended operation at improper
fluid level conditions.

CAUTION: An accurate fluid level check cannot be made unless the

39
 engine is idling (500800 rpm) in N (Neutral), the transmission fluid
is at the proper temperature, and the vehicle is on a level surface.

5.5.2 HOT CHECK

The transmission fluid must be hot to ensure an accurate check, because the fluid
level rises as temperature increases.

To perform a HOT CHECK, do the following:

Be sure fluid has reached normal operating temperature (7193C; 160200F).

If a transmission temperature gauge is not present, check fluid level when the
engine water temperature gauge has stabilized and the transmission has been
operated under load for at least one hour.
Park the vehicle on a level surface and shift to N (Neutral). Apply the parking
brake and allow the engine to idle at 500800 rpm.
Remove the dipstick and wipe clean. Reinsert the dipstick into the transmission.
Remove the dipstick and check the fluid level. The safe operating level is
anywhere within the HOT RUN band on the dipstick.
If the level is not within this band, add or drain fluid as necessary to bring the
level within the HOT RUN band.
Be sure fluid level checks are consistent. Check the fluid level more than once
and if readings are not consistent, check to be sure that the transmission breather
is clean and not clogged. If readings are still inconsistent, contact the nearest
Allison distributor or dealer.

5.6 RECOMMENDED AUTOMATIC TRANSMISSION FLUID AND

VISCOSITY GRADE

Hydraulic fluids (oils) used in the transmission are important influences on

transmission performance, reliability, and durability. TranSynd TM and DEXRON -III
fluids are recommended for all 3000 and 4000 product families applications.

TranSyndTM is a full synthetic transmission fluid developed by Allison Transmission

and Castrol Ltd. This fluid meets Allison specifications for Severe Duty and
Extended Drain Intervals. TranSyndTM is fully qualified to the Allison TES 295
specification and is available through Allison distributors and dealerships.

To ensure the fluid is qualified for use in Allison transmissions, check for the

40
DEXRON -III license numbers on the container or consult the lubricant
manufacturer. Consult your Allison Transmission dealer or distributor before using
other fluid types.

CAUTION: Disregarding minimum fluid temperature limits can

result in transmission malfunction or reduced transmission life.

When choosing the optimum viscosity grade of fluid, duty cycle, preheat
capabilities, and/or geographical location must be taken into consideration. Table 3
lists the minimum fluid temperatures at which the transmission may be safely
operated without preheating. Preheat with auxiliary heating equipment or by
running the equipment or vehicle with the transmission in neutral for a minimum of
20 minutes before attempting range operation.

Viscosity Ambient Temperature Below

Grade Which Preheat Is Required
Celsius Fahrenheit
MIL-PRF-46167 -32 -25
SAE 0W-20* or TranSynd TM -30 -22
DEXRON -III -27 -17
SAE 10W -20 -4
SAE 15W-40 -15 5
SAE 30W 0 32
SAE 40W 10 50
* SAE W designation indicates winter weight based on cold temperature properties
Table 3. Minimum Operating Temperature For Transmission Fluid

41
5.7 KEEPING FLUID CLEAN

CAUTION: Do not use containers or fillers for transmission

fluid that have been used for any antifreeze solution. Antifreeze
and coolant
solutions contain ethylene glycol which, if introduced into the
transmission, can cause the clutch plates to fail.

It is absolutely necessary that transmission fluid be clean. The fluid must be handled
in clean containers to prevent foreign material from entering the transmission.

5.8 FLUID AND INTERNAL FILTER CHANGE INTERVAL

RECOMMENDATIONS

CAUTION: Transmission fluid and filter change frequency is

determined by the severity of transmission service. More
frequent
changes may be necessary than recommended in the general
guidelines when operating conditions create high levels of
contamination or overheating.

Allison requires all 3000 and 4000 product families transmissions to have the main
filter (not
the lube filter or fluid) changed after the first 5,000 miles (8000 km) or 200 hours of
operation, whichever comes first. Refer to SIL 10-TR-99, latest revision, for
convenient kit and fluid information. Refer to service manual Mechanics Tips
for location of the main filter and the filter change procedure.

NOTE: See Terberg Maintenance Manual for more information

42
6 DIAGNOSIS

6.1 DIAGNOSTIC CODES

Continued illumination of the (CHECK) Trans light during vehicle operation (not
start-up) indicates the TCM has signaled a diagnostic code. Poor performance may
activate a code without illuminating the (CHECK) Trans light. Up to five
diagnostic codes can be recorded. Diagnostic codes can be read and cleared by two
methods: by using the Allison DOC for PC-service tool or by using the shift
selector shown below. Use of the Allison DOC for PC-service tool is described in
the instruction manual furnished with each tool. Code reading,clearing methods, and
complete code descriptions are presented in the Troubleshooting Manual, .

Shift Selector / Allison DOC for PC-service tool.

43