Professional Documents
Culture Documents
Parts
2004 AUGUST 01
Catalog CD2150EN
Allison Transmission
VOCATIONAL MODELS
3000 MH 3000 EVS 3500 EVS 3700 SP
3000 TRV 3000 HS 3500 RDS
3000 RDS 3500 SP
3000 PTS
3200 SP
3200 TRV
? Foldout Index Foldout 1. 3000 HS/MH/PTS/TRV and MD 3060/B 300/T 200 Transmissions — Cross Section FO01
Foldout 2. 3500 RDS/EVS/SP and MD 3560 Transmission — Cross Section FO02
Foldout 3. 3700 SP and MD 3070PT Transmissions — Cross Section FO03
Foldout 4. 3000 MH/EVS/RDS/TRV/3200 SP and MD 3060PR/MD 3066PR/B 300PR/B 400PR Transmissions — Cross Section FO04
Foldout 5. 3000 HS/RDS/EVS/MH/PTS/3200 SP and MD 3066/B 400/T 300 Transmissions — Cross Section FO05
? TRADEMARK USE
SERVICE LITERATURE
This service literature provides fully illustrated instructions for operation, maintenance, service, overhaul,
and parts support for your transmission. To ensure maximum performance and service life from your unit,
you may order publications from:
SGI, Inc.
Attn: Allison Literature Fulfillment Desk
8350 Allison Avenue
Indianapolis, IN 46268
TOLL FREE: 888-666-5799
INTERNATIONAL: 317-471-4995
? MODELS COVERED
A complete A/N listing of 3000 Product Family models covered by this catalog can be found starting on
Intro Page 34.
SERVICE KITS
Available service parts kits are listed on Pages 18–30.
NUMERICAL INDEX
A numerical index is included in the rear of this catalog. This index is cross-referenced to indicate the
history of parts. Parts, both current and superseded, appear in numerical order in the Part No. Column.
Current part numbers refer to the figure and reference numbers of the parts. Parts replacing older parts are
followed by the older part number in the history column. Parts that have been replaced are followed by the
part number of the replacing part. Footnote symbols show when a part is replaced by (RB), or when a part
replaces (R) an older part. Parts no longer available from Allison Transmission are followed by three
asterisks (***). Parts not illustrated in the catalog are indicated with NI.
CROSS-SECTION
A typical cross-sectional view of the transmission is shown on foldouts at the back of this catalog.
NOTE: All parts orders must be directed to your dealer — do not send them to Allison
Transmission. Always include the transmission model, the transmission assembly
number, and serial number when ordering parts. Be sure to include part name
and part number.
WARRANTY
Allison Transmission sincerely believes it offers the finest parts warranty in the industry. It is constantly
reviewed to assure it remains competitive. We urge you to ask about it at your local Allison Transmission
Distributor.
? ROTATING CLUTCH
FIGURE 25–1.1 FLEXPLATE AND ADAPTER
FIGURE 24–1.1 Pict
TORQUE CONVERTER
FIGURE 21–1.1
V06157.00.01
ROTATING CLUTCH
FIGURE 25–1.1
MAIN HOUSING
FIGURE 01–1.1
FILL TUBE
FIGURE 02–1.1
V05411.00.01
?
Pict
P1 PLANETARY
FIGURE 14–1.1 P2 PLANETARY
FIGURE 15–1.1
MAIN SHAFT
FIGURE 05–1.1
V05637.00.01
?
Pict
P3 PLANETARY
AND REAR
COVER/RETARDER
FIGURE 39–1.1
V05642.00.01
?
Pict
P3 PLANETARY
AND REAR COVER/RETARDER
FIGURE 39–1.3
V05628.00.01
? CONTROL VALVE
FIGURE 16–1.1
Pict
29
50
36
70
DE
TAC
BE H
FO
CO RE CONN
NTR DR EC
OL OP TO
MO PING R
DU
LE
V06158.01.00
? TRANSFER CASE
FIGURE 22–1.1
Pict
P3 PLANETARY AND
REAR COVER/RETARDER
FIGURE 39–1.1
10
10
.D.
P.E
R
COVE
P.E
.D.
P.E.D.
R ON
AGE COVE USE
STOR IN
P.E.D.
NOT
ACE
R REPL EN
COVE WH
P.E.D. UNIT
E
AGE IN US
STOR NOT
P.E.D.
WHEN
UNIT
R ON
COVE
ACE
REPL
V06181.00.01
? WIRING HARNESSES
FIGURE 70–1.4
Pict
ELECTRONIC RETARDER MODULATION WIRING HARNESSES
CONTROL UNIT REQUEST SENSOR
CONNECTORS CONNECTOR FIGURE 70–1.6
VEHICLE INTERFACE
MODULE CONNECTOR
VEHICLE INTERFACE
WIRING CONNECTOR
CHASSIS
GROUND
WIRING
HARNESS
(CAB)
THROTTLE POSITION
REMOTE SERIAL SENSOR CONNECTOR
INTERFACE
DIAGNOSTIC CONNECTOR
DATA READER
CONNECTOR
ACCUMULATOR
SOLENOID
CONNECTOR
TRANSFER WIRING
CASE HARNESS
CONNECTOR (CHASSIS)
RETARDER
CONTROL BODY SENSOR
CONNECTOR HARNESS
CONNECTOR
TRANSMISSION
OUTPUT SPEED CONNECTOR
SENSOR (PRIOR TO MY ’95)
CONNECTOR
RETARDER CONTROLS
FIGURE 35–1.1 R
N
D
5
E
D
4
O
M
3
2
R
E
D
1
O
M
N
D
V04362.00.02
?
OIL COOLER Pict
FIGURE 20–1.1
120
150
40 250 300
0
10
TRANS
OIL
TEMP
V06159.00.01
?
OIL COOLER
Pict FIGURE 20–1.2
V07028.00.01
?
RETARDER ACCUMULATOR AND PARKING BRAKE
FIGURE 30–1.1 Pict
PTO PROVISION
FIGURE 31–1.2
V06153.00.01
? NOTES
? SERVICE KITS
RECOMMENDED
SPARES FOR UNITS
1–25 26–50 51–200
SK
MASTER OVERHAUL KIT — P/N 29541741 25 50 200
B 400 MODEL TRANSMISSIONS
Part No. Qty Description
11515316 3 Bolt, M6 x 1.0 x 30
12092195 1 O-ring, Connector Assembly, 47.2 mm ID
23019664 2 O-ring, 16.4 mm ID
23043446 11 O-ring, 8.9 mm ID
23045611 1 Sealring, C2, 116.3 mm ID
23045612 1 Sealring, C1, 101.1 mm ID
23045613 1 Sealring, External, C2, 234.1 mm OD
23045614 2 Sealring, C1 and Rear Bearing, 178.8 mm ID
23045615 1 Sealring, Balance Piston, 202.1 mm ID
23045654 1 Sealring, External, C5, 258.7 mm ID
23045816 1 Bearing Assembly, Roller
23045918 1 Bearing Assembly, Thrust Pump
23046228 1 Bearing Assembly, Thrust
23046274 1 O-ring, Turbine Shaft, 25.1 mm ID
23046376 6 Seal, Face
23046437 2 Bearing Assembly, Cone And Roller
23046438 2 Cup, Roller Bearing
23046868 1 Sealring, Lockup Piston, 279.9 mm ID
23047185 1 O-ring, Oil Pump, 110.7 mm ID
23047834 1 Bearing Assembly, Thrust
23047854 5 Bearing Assembly, Thrust
23049377 1 O-ring, Converter Pump-To-Cover, 368.3 mm ID
29500025 1 Sealring, Cast Iron, 61.4 mm OD
29500768 2 Bearing Assembly, Thrust Bearing No. 2
29500822 1 Pin, Retaining, 3 OD x 43 mm
29501469 2 O-ring, 88.6 mm ID
29501538 1 Ring, Retaining, External, Spiral, 46.3 mm ID
29502037 8 Washer, P2 Thrust
29502040 12 Washer, P1 Thrust
29502439 1 O-ring, Flange Button Output, 66.3 mm ID
29503196 1 Bushing
29503197 1 Sealring, Lockup Piston, 86.9 mm ID
29503208 1 O-ring, Converter Cover Plug, 34.6 mm ID
29503225 1 Bearing Assembly, Thrust
29503283 1 Gasket, Case
29503288 1 Gasket, Converter Housing
29503383 2 O-ring, Speed Sensor, 15.4 mm ID
29503547 1 Gasket, Cooler Port Cover
29506386 1 Retainer, Locknut
29506484 1 Switch, Pressure
29507437 2 O-ring, 75.9 mm ID
RECOMMENDED
SPARES FOR UNITS
1–25 26–50 51–200
SK MASTER OVERHAUL KIT — P/N 29541741 (cont’d) 25 50 200
B 400 MODEL TRANSMISSIONS
Part No. Qty Description
29507528 1 Seal Assembly, Oil Input
29507823 2 Seal, Fill Tube
29510682 1 Sealring, Internal, C5, 140.3 mm OD
29511406 8 Washer, P3 Thrust
29512791 1 Washer, Sealring
29512875 1 O-ring, Retaining Plate Bolt, 12.3 mm ID
29515690 1 Seal Assembly, Oil Output
29520396 1 Seal, Feedthrough Standoff
29521240 5 Sealring, External, 88 mm OD
29524120 3 Sealring, External
29524121 2 Sealring, External
29524335 1 Bushing, Gear Set
29524448 2 O-ring, 85.3 mm ID
29524449 2 Gasket, Filter Cover
29530092 1 Damper Assembly
29531003 1 Bushing, P1 Sun Gear Drive Hub, 68.164 mm ID
29531004 1 Bushing, 43.104 mm ID
29531005 1 Bushing, 20 mm ID
29532361 1 Instruction Sheet No. 278
29533975 1 Bushing, 75.15 mm ID
29534354 1 Gasket, Rear Cover
29534493 1 Hub Assembly, Rotating Clutch, Complete
29534574 1 Plate, C1 Clutch Pressure
29535213 1 Plate, Retaining
29535219 1 Bolt, Hx, M14 x 2 x 70
29535223 1 Spacer, Output
29535230 1 Gasket, Channel Plate
29535234 1 Shaft Assembly, Output
29536334 6 Plate, C1 Clutch Friction
29536335 6 Plate, C2 Clutch Friction
29536336 10 Plate, C3 Clutch Friction
29536337 7 Plate, C5 Clutch Friction
29536343 5 Plate, C1 Clutch Reaction
29536344 6 Plate, C2 Clutch Reaction
29536345 9 Plate, C3 Clutch Reaction
29536346 8 Plate, C5 Clutch Reaction
29536567 4 Ferrule, Oil Level Sensor Viton®
29536722 2 Solenoid, N/O
29536860 1 Filter Assembly, Suction
29537066 1 Gasket, Suction Filter
29537369 1 Solenoid Assembly
RECOMMENDED
SPARES FOR UNITS
1–25 26–50 51–200
MASTER OVERHAUL KIT — P/N 29541741 (cont’d) 25 50 200
SK
B 400 MODEL TRANSMISSIONS
Part No. Qty Description
29537371 4 Solenoid, N/C Modulating
29537939 1 Ring, P1 Indexing
29537940 1 Ring, P2 Indexing
29537941 1 Ring, P3 Indexing
29538231 2 Filter, Oil
29538477 1 Stop, Converter Regulator
29539665 1 Backplate, C1
29540476 1 Instruction Sheet No. WT-108
29540483 2 Clutch Piston And Seal, C3/C4
29541560 1 Instruction Sheet No. 299
29541563 8 Bearing Assembly, P3 Carrier
29541564 8 Bearing Assembly, Roller
29541565 12 Bearing Assembly, Roller
29541736 1 Seal Assembly, Oil
RECOMMENDED
SPARES FOR UNITS
1–25 26–50 51–200
SK MASTER OVERHAUL KIT — P/N 29541740 (cont’d) 25 50 200
B 400 MODEL TRANSMISSIONS WITH RETARDER
Part No. Qty Description
29500025 1 Sealring, Cast Iron, 61.4 mm OD
29500768 2 Bearing Assembly, Thrust Bearing No. 2
29500822 1 Pin, Retaining, 3 OD x 43 mm
29501469 2 O-ring, 88.6 mm ID
29501538 1 Ring, Retaining, External, Spiral, 46.3 mm ID
29502037 8 Washer, P2 Thrust
29502040 12 Washer, P1 Thrust
29502439 1 O-ring, Flange Button Output, 66.3 mm ID
29503196 1 Bushing
29503197 1 Sealring, Lockup Piston, 86.9 mm ID
29503208 1 O-ring, Converter Cover Plug, 34.6 mm ID
29503225 1 Bearing Assembly, Thrust
29503283 1 Gasket, Case
29503288 1 Gasket, Converter Housing
29503383 2 O-ring, Speed Sensor, 15.4 mm ID
29503531 1 Sensor, Speed
29503547 1 Gasket, Cooler Port Cover
29503714 2 Sealring, Rotating
29503757 1 Gasket, Solenoid Cover
29506386 1 Retainer, Locknut
29506484 1 Switch, Pressure
29507437 2 O-ring, 75.9 mm ID
29507528 1 Seal Assembly, Oil Input
29507752 1 Gasket, Channel Plate
29507823 2 Seal, Fill Tube
29508020 1 Gasket, Retarder Housing
29510499 1 O-ring, 22.0 mm ID
29510682 1 Sealring, Internal, C5, 140.3 mm OD
29511406 8 Washer, P3 Thrust
29512747 2 Gasket, Separator Plate
29512791 1 Washer, Sealring
29512875 1 O-ring, Retaining Plate Bolt, 12.3 mm ID
29520396 1 Seal, Feedthrough Standoff
29521240 5 Sealring, External, 88 mm OD
29524120 3 Sealring, External
29524121 2 Sealring, External
29524335 1 Bushing, Gear Set
29524448 2 O-ring, 85.3 mm ID
29524449 2 Gasket, Filter Cover
29529486 1 O-ring, 31.5 mm ID
29530092 1 Damper Assembly
RECOMMENDED
SPARES FOR UNITS
1–25 26–50 51–200
MASTER OVERHAUL KIT — P/N 29541740 (cont’d) 25 50 200
SK
B 400 MODEL TRANSMISSIONS WITH RETARDER
Part No. Qty Description
29531003 1 Bushing, P1 Sun Gear Drive Hub, 68.164 mm ID
29531004 1 Bushing, 43.104 mm ID
29531005 1 Bushing, 20 mm ID
29532361 1 Instruction Sheet No. 278
29533975 1 Bushing, 75.15 mm ID
29534493 1 Hub Assembly, Rotating Clutch, Complete
29534574 1 Plate, C1 Clutch Pressure
29535213 1 Plate, Retaining
29535219 1 Bolt, Hx, M14 x 2 x 70
29535223 1 Spacer, Output
29535230 1 Gasket, Channel Plate
29535234 1 Shaft Assembly, Output
29535940 2 Gasket, Separator Plate
29536334 6 Plate, C1 Clutch Friction
29536335 6 Plate, C2 Clutch Friction
29536336 10 Plate, C3 Clutch Friction
29536337 7 Plate, C5 Clutch Friction
29536343 5 Plate, C1 Clutch Reaction
29536344 6 Plate, C2 Clutch Reaction
29536345 9 Plate, C3 Clutch Reaction
29536346 8 Plate, C5 Clutch Reaction
29536567 4 Ferrule, Oil Level Sensor Viton®
29536722 2 Solenoid, N/O
29536728 1 Gasket, Retarder Housing Cover
29536742 1 Gasket, Retarder Housing
29536766 1 Gasket, Jumper Manifold
29536860 1 Filter Assembly, Suction
29537066 1 Gasket, Suction Filter
29537080 1 Instruction Sheet No. 294
29537369 1 Solenoid Assembly
29537371 4 Solenoid, N/C Modulating
29537373 1 Solenoid
29537643 1 Plate, Solenoid Separator
29537867 1 Gasket, Adapter Housing
29537939 1 Ring, P1 Indexing
29537940 1 Ring, P2 Indexing
29537941 1 Ring, P3 Indexing
29538231 2 Filter, Oil
29538477 1 Stop, Converter Regulator
29539665 1 Backplate, C1
29540476 1 Instruction Sheet No. WT-108
RECOMMENDED
SPARES FOR UNITS
1–25 26–50 51–200
SK MASTER OVERHAUL KIT — P/N 29541740 (cont’d) 25 50 200
B 400 MODEL TRANSMISSIONS WITH RETARDER
Part No. Qty Description
29540483 2 Clutch Piston And Seal, C3/C4
29541560 1 Instruction Sheet No. 299
29541563 8 Bearing Assembly, P3 Carrier
29541564 8 Bearing Assembly, Roller
29541565 12 Bearing Assembly, Roller
29541736 1 Seal Assembly, Oil
RECOMMENDED
SPARES FOR UNITS
1–25 26–50 51–200
STRAIGHT THROUGH SEAL AND GASKET KIT — P/N 29543319 (cont’d) 25 50 200
SK
3000 PRODUCT FAMILY TRANSMISSIONS. See SIL 27-WT-96.
Part No. Qty Description
29524121 2 Sealring, External
29532361 1 Instruction Sheet No. 278
29534354 1 Gasket, Rear Cover
29535219 1 Bolt, Hx, M14 x 2 x 70
29535223 1 Spacer, Output
29535634 2 Washer, Belleville
29535692 2 Bolt, M10 x 1.5 x 30, Socket Head
29540483 2 Clutch Piston And Seal, C3/C4
29540989 1 Seal Assembly, Output
RECOMMENDED
SPARES FOR UNITS
1–25 26–50 51–200
SK MAINTENANCE (FILTER) KIT — P/N 29540493 25 50 200
USE WITH 3000 PRODUCT FAMILY TRANSMISSIONS WITH 2 INCH OR 7 INCH SUMP
Part No. Qty Description
23019664 1 O-ring, Drain Plug, 16.4 mm ID
29501469 2 O-ring, Cover, 88.6 mm ID
29507437 2 O-ring, Cover, 75.9 mm ID
29524448 2 O-ring, 85.3 mm ID
29524449 2 Gasket, Filter Cover
29538231 2 Filter
29540476 1 Instruction Sheet, Assembly, No. WT-100
RECOMMENDED
SPARES FOR UNITS
1–25 26–50 51–200
SK
REMOTE FILTER CONVERSION KIT — P/N 29542032
USE STARTING WITH S/N 6510069120. SEE SIL 12-WT-04. 4 8 20
Part No. Qty Description
23019664 1 O-ring, 16.4 mm ID
29507437 2 O-ring, 75.9 mm ID
29524448 2 O-ring, 85.3 mm ID
29524449 2 Gasket, Filter Cover
29540197 2 Cover, Filter
29541709 1 Housing Assembly, Remote Filter
29542037 1 Instruction Sheet No. 312
RECOMMENDED
SPARES FOR UNITS
1–25 26–50 51–200
SK
TRANSFER CASE OUTPUT BEARING SHIM KIT — P/N 29503821 25 50 200
USE WITH 3700 SP/MD 3070PT
Part No. Qty Description
29503820 1 Instruction Sheet No. WT-107
29505947 3 Shim, 0.254 mm (0.010 inch)
29505948 3 Shim, 0.127 mm (0.005 inch)
29505949 3 Shim, 0.076 mm (0.003 inch)
TRANSFER CASE DRIVE OR DRIVEN GEAR BEARING KIT — P/N 29503823 25 50 200
USE WITH 3700 SP/MD 3070PT
29502105 3 Shim, 0.254 mm (0.010 inch)
29502106 3 Shim, 0.127 mm (0.005 inch)
29502107 3 Shim, 0.076 mm (0.003 inch)
29503818 1 Instruction Sheet No. WT-105
TRANSFER CASE OVERHAUL SEAL AND GASKET KIT — P/N 29537869 25 50 200
USE WITH 3700 SP/MD 3070PT
Part No. Qty Description
23043446 3 O-ring, 8.92 mm ID
29500969 2 O-ring, 26.6 mm ID
29501189 1 Sealring, C6 Piston, Outer, 192.3 mm ID
29501190 1 Sealring, C6 Piston, Inner, 94.3 mm OD
29502161 1 Sealring, Differential Clutch Piston, Internal
29502164 1 Sealring, Differential Clutch Piston, External
29502846 1 O-ring, 20.4 mm ID
29503336 2 Seal Assembly, Oil Output
29503380 1 O-ring, Solenoid Small, N/C, 9.3 mm ID
29503382 1 O-ring, Solenoid Large, N/C, 14.0 mm ID
29506211 2 Gasket, Idler Cap
29506212 1 Gasket, Valve Cover
29506213 2 Gasket, Output Housing
29506215 2 O-ring, Idler Cover
29506323 1 Gasket, Transfer Case-To-Adapter Housing
29506352 1 Gasket, Connector
29506399 1 Sealring Kit. Kit Contains Three Sealrings
P/N 29506216
RECOMMENDED
SPARES FOR UNITS
1–25 26–50 51–200
TRANSFER CASE OVERHAUL SEAL AND GASKET KIT — P/N 29537869 (cont’d) 25 50 200
SK
USE WITH 3700 SP/MD 3070PT
Part No. Qty Description
29532361 1 Instruction Sheet No. 278
29537001 1 Gasket, Front And Rear Case
29537003 1 Gasket, C6 Clutch Housing
29537867 1 Gasket, Stator Housing
RECOMMENDED
SPARES FOR UNITS
1–25 26–50 51–200
RETARDER SEAL AND GASKET KIT — P/N 29541738 (cont’d) 25 50 200
SK
USE WITH 3000 PRODUCT FAMILY ON-HIGHWAY TRANSMISSIONS
PRIOR TO S/N 6510142342. See SIL 27-WT-96.
Part No. Qty Description
29503714 2 Sealring, Rotating
29503757 1 Gasket, Solenoid Cover
29507752 1 Gasket, Channel Plate
29508020 1 Gasket, Retarder Housing
29510499 1 O-ring, 23.5 mm ID
29510682 1 Sealring, Internal, 140.3 mm OD
29511437 2 O-ring, Output Bolt, 9.1 mm ID
29512747 2 Gasket, Separator Plate
29512875 1 O-ring, Output Bolt, 12.3 mm ID
29529486 1 O-ring, 31.5 mm ID
29532361 1 Instruction Sheet No. 278
29535219 1 Bolt, Hx, M14 x 2 x 70
29535223 1 Spacer, Output
29535634 2 Washer, Belleville
29535692 2 Bolt, M10 x 1.5 x 30, Socket Head
29537867 1 Gasket, Stator Housing
29541736 1 Seal Assembly, Oil
RECOMMENDED
SPARES FOR UNITS
1–25 26–50 51–200
RETARDER SEAL AND GASKET KIT — P/N 29541739 (cont’d) 25 50 200
SK
USE WITH 3000 PRODUCT FAMILY ON-HIGHWAY TRANSMISSIONS
STARTING WITH S/N 6510142342. See SIL 27-WT-96.
Part No. Qty Description
29535634 2 Washer, Belleville (Output Bolt)
29535692 2 Bolt, M10 x 1.5 x 30 Socket Head (Output Bolt)
29535940 2 Gasket/Separator Plate
29536728 1 Gasket, Retarder Housing Cover
29536742 1 Gasket, Retarder
29536766 1 Gasket, Jumper Manifold
29537080 1 Instruction Sheet No. 294
29537643 1 Plate, Retarder Separator
29537867 1 Gasket, Stator Housing
29541736 1 Seal Assembly, Oil
Code Explanation
MD 3 0 6 0 PR RM
RM Remanufactured transmission
P PTO provision
R Retarder
T Transfer case
0 Major revision
0 Close ratio
5 Wide ratio
3 Transmission series
Code Explanation
B 300, 400 PR RM
T 200, 300 PR RM
RM Remanufactured transmission
P PTO provision
R Retarder
200, 300 or 400 Transmission series
B Automatic bus transmission
T Automatic bus transmission outside North America only
V07274
VOCATIONAL MODELS
Code Explanation
3 0 0 0 HS
HS — Highway Series
MH — Motorhome Series
SP — Specialty Series