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#1098, Rev. D
August, 2012
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Transmission Fluid and Filter Service Recommendations

MODELS AFFECTED:

5000, 6000, 8000, 9000 Series OffHighway Transmissions

Introduction:
Offhighway transmissions require proper transmission uid and regular uid system maintenance for optimum
performance, durability, and reliability. Fluid selection is inuenced by operating environment and duty cycle. The
severity of transmission service and the type of uid, lter assembly, and lter elements determine the uid
and lter change intervals. This document summarizes the current Allison OffHighway Transmission uid and
lter service recommendations.

Transmission Fluid Recommendations:


Allison Transmission, Inc. recommends only uids meeting Allison Type TES439 specication for use in 5000,
6000, 8000, 9000 Series OffHighway transmissions. The current TES439 uids approved by Allison are available
via the Allison website www.allisontransmission.com.
Acceptable oils may include some synthetic types and some engine oils as described in SAE standard J300
Engine Oil Viscosity Classication as follows:
SAE 0W30
SAE 0W40
SAE 30
SAE 5W40
SAE 10W40
SAE 15W40
SAE 40
This list is also available from Allison Transmission Distributors or Dealers. Before using any uid, check that it is
listed in the TES439 Approved Fluids List.
As TES439 is a new specication, and as it will take some time to populate the approved TES439 oils list, oils of
the above viscosities found listed on the previous C4 approved oils list found on the Allison Transmission, Inc.
website are also acceptable at this time. Once the TES439 approved list is populated, the C4 list will be cancelled.
Higher viscosity uids, such as SAE 30W or SAE 15W40 oils are recommended for optimum transmission life
in 5/6/8/9000 OffHighway transmissions. When choosing the optimum viscosity grade of uid to use, consider
geographic location and preheat requirements. Proper viscosity grade selection is important for transmissions
when operating the transmission in conditions below a uids minimum operating temperature. Preheat or uid
FS / SL5533EN

332932

Copyright 2012 Allison Transmission, Inc. All Rights Reserved.

#1098, Rev. D
August, 2012
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warmup is required when operating Allison transmissions below the uids minimum critical temperature, which is
viscosity grade dependent. Table 1 lists a number of lower viscosity uids for consideration when operating in
low ambient conditions and lists the minimum uid temperatures below which preheat or warmup are required.
If preheating is necessary, use either auxiliary heating equipment, or warmup the transmission by starting the
engine with the transmission in N (Neutral), and operating at the engine low idle speed for a minimum of twenty
minutes before attempting range operation. If cold weather starting is not a factor and/or the transmissions are
operating in a warm/hot environment, the higher viscosity uids are recommended.
CAUTION: Disregarding minimum uid temperature limits can result in transmission malfunction or
reduced transmission life.

Table 1. Minimum Operating Temperature (without preheat)


SAE Viscosity Grade

Degrees (C)

Degree (F)

SAE 0W30

30

22

SAE 15W40

15

SAE 30

32

SAE 40

10

50

Transmission Fluid Change Interval:


Fluid analysis is the preferred method for determining the transmission uid change interval. Monitor the oxidation
level according to the measurement limits shown in Table 2. The uid is still usable if it meets both limits in
Table 2. If uid analysis cannot be utilized, change the uid every 1200 hours of operation when using TES439
Fluids (refer to Table 3.)
NOTE: A Fluid Analysis Kit P/N 29537805 is available from Allison Transmission, Inc.

Table 2. Fluid Oxidation Measurement Limits


Measurement

Limit

Viscosity

+/ 25% change from new uid

Total acid number

+3.0 change from new uid

Consult your local industrial yellow pages for uid analysis rms. Use one uid analysis rm as results from various rms
cannot be accurately compared.

When servicing any transmission, visually inspect the uid at the sample and drain locations for dirt, metal, or
coolant contamination. More frequent uid changes may be required if the uid is visually contaminated, if the
environment produces high levels of contamination, if the duty cycle subjects the unit to frequent overheating, or if
uid analysis indicates that the uid is oxidized beyond the limits in Table 2.

Copyright 2012 Allison Transmission, Inc. All Rights Reserved.

#1098, Rev. D
August, 2012
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Table 3. Standard Fluid Change Intervals (by Fluid Type)
Transmission Model
5000, 6000, 8000, 9000 Series

Fluid Recommendation

Drain Interval (hrs)

TES439 Fluids

1200 hours

C4 Fluids

1200 hours

Filter Element Change Intervals and Service:


Filter element change intervals are determined by the model lter assembly and lter elements used. The
current High Efciency Filter Assembly, released to production built 5000, 6000, 8000, 9000 series OffHighway
transmissions in late 1984 (reference SIL 22TR84) uses a berglass media rated nominally at 6 micron. The
former AC lter used a cellulose media nominally rated at 2540 micron. For the purposes of this letter, only the
current High Efciency Filter Assembly will be discussed.
NOTE: The charging pump screen located in the transmission sump is an oil strainer and need only be
serviced at overhaul.
If the lter change interval cannot be monitored with the deltaP switch as described below, change the lter
elements whenever the uid is changed and at 600 hour intervals between uid changes.
Allison HighEfciency lter assemblies are equipped with a differential pressure (deltaP) switch to indicate when
the lter element requires service. This serves two important functions it allows the actual change interval to be
determined for each customers application, and is a good service requirement indicator. The deltaP switch senses
the pressure difference between the unltered uid entering the ltration media and the ltered uid exiting the
ltration media and acts as a cumulative particle counter indicating when the lter elements are plugged with
ltration debris and must be changed. Cumulative Particle Counter refers to the debris suspended in the uid
that is captured by the ltration media. This debris varies in size down to the lter element rating. For the case of
Allison HighEfciency Filters, that value is nominally considered to be 6 micron. When enough particles have
been captured by the element, the cumulative amount creates enough restriction in the ltration element to
generate a pressure differential sufcient to activate the differential pressure (deltaP) switch, which is set to a
35 psi differential rating. Sustained operation after the indication point will cause the lter bypass valve to open,
allowing unltered uid to circulate into the transmission.
CAUTION: For Allison HighEfciency direct and remotemount transmission main circuit lters, the
integral bypass valves are located in the lter base. Inspect the bypass valves whenever the lter
elements are changed. A visual check must show the bypass valve squarely seated in the lter housing. If
the valve is cocked, loose, or missing, replace the lter base assembly.
This following procedure applies to Allison HighEfciency lters and lter elements supplied with transmissions
built 1984 and later and those transmissions that have had the HighEfciency Filter system retrotted onto
earlier built units.
Filter elements capture debris suspended in the uid generally from two sources. These two sources are
contaminates from the transmission / cooler circuit and from the uid itself. The debris amounts are highest when a
new or newly rebuilt transmission is installed or an oil change has just occurred. Shorter than normal lter service
life may be experienced in these conditions due to the uid being ltered to the level of the Allison HighEfciency
lter. However, each successive element should provide longer service life. When replacing the lter element,
do not change the transmission uid unless the uid is visibly contaminated. New transmission uid is generally
Copyright 2012 Allison Transmission, Inc. All Rights Reserved.

#1098, Rev. D
August, 2012
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contaminated above the 6micron level and changing the uid unnecessarily may actually add contaminates
resulting in reduced lter element life. One way to maximize lter service life would be to prelter the replacement
uid before or while adding it to the transmission. If problems persist, check with the uid supplier or perform a uid
analysis of the new uid. By changing the element(s) before indication by the deltaP switch, signicant usage of
the lter can be wasted and is not cost effective. Additionally, by changing the element prematurely, a vital source
of wear contamination information is lost, or at least distorted.
NOTE: Monitoring the actual lter element service life to the indicated change point as determined by the
deltaP switch indication allows the general condition of the transmission internal wearing components
to be determined.
After system cleanup, the lter elements provide longservice life in a normally functioning transmission. A normally
functioning transmission does not generate debris that needs to be removed by the lter element. As the internal
wearing components inside the transmission begin to deteriorate, the service life of the lter element is measurably
shorter due to the ltering out of the debris from the deteriorating component. When this occurs, the transmission
does start to generate debris.
NOTE: Measurable premature lter element deltaP indications may be utilized as an early warning signal
that a preventive maintenance repair is advisable to prevent excessive consequential damage.
Due to the signicant costofoperation advantage that can be achieved by monitoring the deltaP switch system,
it is recommended that the proper function of this system be monitored on a periodic preventive maintenance
schedule. A test block to activate the switch is shown in Figure 4.

Technical Information:
For detailed information on transmission uid characteristics, analysis, and selection, refer to Automatic
Transmission, Inc. Fluid Technicians Guide (GN2055EN), available from any Allison Transmission Distributor or
Dealer.

Service Information:
For complete uid and lter change procedures, refer to the appropriate service manual:
SM1228EN

8000 Series Transmissions Service Manual

SM1833EN

9000 Series Transmissions Service Manual

SM1866EN

5000/6000 Series Transmissions Service Manual

Copyright 2012 Allison Transmission, Inc. All Rights Reserved.

#1098, Rev. D
August, 2012
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Figure 1. DirectMount Filter Base

Figure 2. RemoteMount Filter Base

Copyright 2012 Allison Transmission, Inc. All Rights Reserved.

#1098, Rev. D
August, 2012
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Figure 3. Bypass Valve Seated in Filter Base

Copyright 2012 Allison Transmission, Inc. All Rights Reserved.

#1098, Rev. D
August, 2012
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Copyright 2012 Allison Transmission, Inc. All Rights Reserved.

Figure 4. Test Block

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