2014 JULY ‘SM7463EN Allicon Tranemission OFF-HIGHWAY MODELS 5000 and 6000 Product Families H5620A(R) — M5620A(R)——§ 5620AR $ 5620M $ 6620Hi H6620(R) —- MG620A(R) ——-S S82OH(R) «S$ 6620A S 6620M Allison S@Aluson 7 ortat isuropta nana AccsonAllison 5000 and 6000 Product Families IMPORTANT SAFETY INFORMATION TIS YOUR RESPONSIBILITY tobe completay familar wit) the warnings and caution in his manual. ‘Those warnings and cautions advise of spectic methods or acions that can result in personal nj. ‘equpment damage, or cause the equipment to become unsafe. These warnings and cautions are not ‘exhaustive. Alsen Transmission could not possily now, evaLale, or advise the service trade ofall ‘conceivable procedures by which service might be performed cof the possible hazardous consequences of ‘each procedure, Accordingly, ANYONE WHO USES A SERVICE PROCEDURE OR TOOL WHICH IS NOT. RECOMMENDED BY ALLISON TRANSMISSION MUST frst be thoroughly satisfied that neither personal ‘Safety nor equipment safety wl be jeopardized bythe service methods ueed Vehicle manufacturers integrate Alson transmissions ino vais used fora variety of vocations and services. The vehicle manufacturers responsible fr Wentiyng the specific operating conditions to which the vehicle wil be subjected and to communicate the appropre meane for preventing unintended vehicle ‘movement witin hose cons, in orgrto ensure vehicle and operator safely, Tho vehicle owner and, ‘operator should be aware of and follow the vehicle manutactre”s operating intucons and warnings related {0 parking and preventing unintended vehicle movement. Proper service and repair is important ta th safe and reliable operation of the equipment. The service procedures recommended by Alison Transmission (or the vehele manufacturer) and described inthis ‘manual ar effective methods fr performing service and diagnos operations. Some procedures require Using specially designed tools. Use special tools when and inthe manner recommended. ‘The WARNINGS, CAUTIONS, and NOTES in his manual ppl only ta he Alson transmission and not {o other vehicle systems which may intract wih tho vansmisson. Be sure to review and cbverve any vehicle system information provided bythe vehicle manufacturer andlor body bude ta ims the Alison transmission is boing serviced WARNINGS, CAUTIONS, NOTES ‘Three types of headings are used in thie manual to attract your attention: 'NOTE: Anole is used when an operating procedure, price, etc, je essential to highlight Copyright © 2014 Atoon Taam, In A Rigs Reserve. ®‘Allison 5000 and 6000 Product Families ABBREVIATIONS AND ACRONYMS 7 cEe2 ‘Commercial Elecrenic Cantos 2 [ceca “Commercial Electronic Contos a = OND Display ModerBiagnosc = ore Diagnostic Trouble Code 7 “pres ‘Diagnostic Trouble Codes a : 7 EMI Electromagnets ntrerence + Foe Federal Communications Commission 0 inside Diameter er a CT | +00 ‘Outside Diameter 7 OEM ‘Original Equipment Manufacturer = OLS ‘Ol Lovel Sensor ps7 Pounds per Square Inch 7 PTO Powor Takeo RFT Radio Frequency interfere aml ‘om Revoltions Per Minute mi 7 SAE ‘Society of Aviomative Engineers i a “Senice Information Later . >TAN “Total Acid Number [TCM 7 Transmission Control Wodule = TR “Tata Indicated Runout wit Venice interface Module + vw ‘Vehicle interface Wiring ” copy © 2014 Allee Tasmnsln, he AI Fights Reserved,Allison 5000 and 6000 Procuct Families TRADEMARK USAGE ‘The following trademarks are the property cf the companies indcated + Alison Diagnostic Optimized Connector (Alison DOC) ea registered trademark of Alison “Transmission, ine. + BoborJF* isthe registred trademark for abicogical inhibitor manufactured by Hammonds Fuel ‘Addives Company. + Spiralock is rgistered trademark of Spiraock of Michigan, + Tellon is a registred trademark ofthe DuPont Corporation. + TranSynd® isa registored trademark of General Motors Corporation. + Mion isa registered trademark of DuPont Corporation + Pormatox® is rogitored trademark of line Tool Work, ie + Lubsiplato® i a rogstred trademark of Lubpiate Lubricants Company, LITERATURE Alison Transmission, Inc. service Iterature providos fly iusretod instructions fr operation, maintenance, ‘woubleshooting, sonice, overhaul, and parts support for your transmission, For maximum performance and ‘service ie from your unt, you may erdr adeitonal publicators va fax, phone or web, FAO 317-471-4906 ‘TOLL FREE: 888-606-5790 INTERNATIONAL: 317-471-499 wn.alicontranemissionpublcations.com 'NOTE: Surcharge willbe applied for ordre placod via phone or FAK Copy © 2014 Azan Tanaieion, In Al Rights Roser. v‘Allison 5000 and 6000 Product Families LIST OF WARNINGS ‘This manual contains the following wamings— TT IS YOUR RESPONSIBILITY TO BE FAMILIAR WITH ALL OF THEM. + To help avoid injury and property damage caused by sudden and unexpected vehicle movement, donot begin a stationary stall test until your + Put the transmission in N (Neutra). and + Set the parking brake and service brakes, and mato sure they are properly engaged. and + Chock the wheels and take any other steps necessary to keep the vehicle from ‘moving... and + Warn people to koop clear ofthe vehic dts path. + To help provent personal injury or property damage caused by suddon and unexpected ‘ohicle movement, da not check the fluid unt you: + Put the transmission in N (Noutra)..and + Apply the parking brake and emergency brakes and make sure they are property ‘engaged...and + Chock the wheels and take any other steps necessary to keep the vehicle from moving + To help avoid injury or property damage caused by susiden and unexpected. ‘movement, do not perform maintenance or service procedures unt + The transmission isin N (Neutral). tlpeent “The parking brake and service brakes are set ané properly engaged. + The wheels are chocked. + Any other steps necessary to keep the equipment from moving have boon performed. + The normal operating temperature of transmission ful is 190-200°F (82-93°C) andit can be hotter Hot fuid can cause severe burns and eye injures. To help avoid personal injury when making hot fluid level checks, AVOID CONTACT INITH HOT FLUID BY WEARING HEAVY GLOVES AND SAFETY GLASSES, REMOVE CHECK P_UGS VERY SLOWLY, AND DO NOT ‘STAND DIRECTLY IN FRONT OF CHECK PLUGS BEING REMOVED. + To help avoid personal injury, such as burns, from ho! transmission fluid andlor to help avoid equipment damage, do not stall the torque converter for more than ton seconds ‘maximum and monitor transmission fluid temperature. Immediataly return the engine to idle if converter out (to cooler temperature exceeds 180°C (300°F). Operating the transmission at high engine power at transmission stall or near stall conditions causes a rapid rise in th transmission fluid temperature. The ud inthe transmission torque converters absorbing all ofthe engine power and the vehicle cooling systems cannot dissipate the excessive heet Toad. Extended operation under high heat load conditions causes transmission and cooling systom damage, and can possibly fall hydraulic lines causing leaking high temperature fu “ Copy © 2014 Allon Tranamislon ne. Rights ReservedAllison 5000 and 6000 Product Families LIST OF WARNINGS (cont'd) ‘This manual contains the folloving warnings— {TIS YOUR RESPONSIBILITY TO BE FAM! R WITH ALL OF THEM, + To help avoid personal injury and equipment damagewhile conducting a transmission stall test, the vehicle must be positively prevented from moving. Apply the parking brake, the service brake, and chock the wheels securely. Wan personnel to keep clear ef the vehicle ‘and is travel path + To help avoid personal injury andlor equipment damego, a driving transmis "must be performed by a trained driver and a qualified technician. + Use appropriat safety equipment such as safety glasses, safety shoes, and gloves. Do not burn discarded Teflon” seals. Toxle gases are produced by burning Telon®. + Never dry bearings by spinning thom with compre lsintograte, allowing balls or rollers to become ‘bearing witiout lubrication ean damage the be 0d alt. A sploning bearing can il fying projectiles. Also, spinning a ng ‘Avoid contact with the hot fluid or the sump when drsning transmission fluid, Dect contact With the hot Mulder the hot sump may resut In Beal injury. ‘To prevent personal injury andlor tanemission damage, use a hoist and iting fixture when, iting, removing, or installing a transmission. Be sur the liting equipment can propery ‘support the woight ofthe transmission. + Lifting the tywhes! assembly from the transmission can dislodge lockup clutch parts from ‘the housing oF assembly. To avoid injury from faling parts, stay clear ofthe area beneath {he raised components and do not attempt to hold the parts in the housing or assembly using your hands. ‘The cadmlum-plated material used in the brazed joins of the main-pressure hose fitin produces toxic yellow-brown gases when welded. Exposure to these gases is extromely hhazardous and can be fatal. Do not attempt to repair 1080 iting joints by welding. Iterforence between the main-pressure transfer tube assembly hose and the equipment causes binding and abrasion ofthe hose. Failure of sn abraded hose releases pressurized, Peatedfuid (pressures and tomperatures in the assembly can exceed 350 psi (2413 KPa) and 215° (135°C). To help avoid injury due to hose fallue, prevent physical contact between the hose and equipment when installing the transfer tube assembly. ony © 2014 Aeon Transmssion, Ie Al Rigs Reserved‘Allison 5000 and 6000 Product Families Notes ‘Copy © 2014 Aton Tranemisn,‘TABLE OF CONTENTS IMPORTANT SAFETY INFORMATION [ABBREVIATIONS AND ACRONYMS TRADEMARK USAGE. UTERATURE . UST OF WARNINGS Section 1. GENERAL INFORMATION 4-4. SCOPE OF MANUAL, coverage Itai Maintenanc Intrmation 112, SUPPLEMENTARY INFORMATION 4-9. ORDERING PARTS: “Transmission Namepiate Parts Catalog 14. DESIGN FEATURES “Transmissonto-Engine Couping “Torque Converter Pranetary Gearing Hyeraute System Power Takoot (PTO) Lookup Chtch b anual lectie Shit Electron Cont Sit ManuabHyraile Sit 16, OPTIONS 4 ao yout Retarder Parking Broke “Trantor Gears (Dropbox) uiput Disconnects Flanges ‘Specdometa Drive +7. pIAGNosTIcs "4 14 6 15 15 15 18 18 15 1s 16 6 16 16 7 7 “7 Ww W W 18 v0, 192, 118, 14, 116, 146, Before Starting 1 CHECK TRANS Light Preservation and Storage 2. Storage, Now Transmission (Prior io natalia) 4. Prosenation Methods Storage, One Yoar—hhout “Transmission Fis 4 Storage, One Yoar—th Transmssion id (Momaly Insta in tho Equpment) «Resting Tansmision to Service RESTORING TRANSMISSION TO 4 Transmission Exterior . Sealed Breater and Openings (New Transmissions 4 Stored Without Fad Stored Win Fas OPERATING INSTRUCTIONS 2. Operator's Manual SPECIFICATIONS AND DATA, LECTROMAGNETICIRADIO FREQUENCY INTERFERENCE ‘MELDING ON VEHICLE PAINTING ON VEHICLE 2. ELECTROSTATIC PAINTING. >. PAINTING OF TRANSMISSION CONTROL COMPONENTS. ENVIRONMENT JUMP STARTING 17 7 “7 “7 18 19 19 19 19 +9 19 19 19 115 146 146 146 146 7 Section 2. DESCRIPTION AND OPERATION 2 22 SCOPE MOUNTING, INPUT DRIVES 8. Remote Mounting Diet Moving Cop © 2014 Alsen Tasminsion, ie. Al Fights Reseed 2 2a a4 2‘Allison 5000 and 6000 Product Families 23 25, 26. 28 2a 22, 213, Lockur cuuToH a, Description. b. Operation ‘TORQUE CONVERTER a, Deserpion. b. Operation HYDRAULIC RETAROER 1. Description b. Operation POWER TAKEOFF (PTO) DRIVES. 1. Desergion , Operation SPLITTER CLUTCHES, GEARING 1. Desergton Operation HIGHRANGE CLUTCH (FIETH AND ‘SIXTH RANGE) ‘. Desergtion . Operation INTERMEDIATE: RANGE CLUTCH, PLANETARY (THIRD AND FOURTH RANGE) a. Deserpton . Operation , LOW-RANGE CLUTCH, PLANETARY (FIRST AND SECOND RANGE) 1. Description . Operation REVERSE CLUTCH PLANETARY |. Description ». Operation ‘SPEEDOMETER DRIVE (SOME VEHICLE MoveLs) a. Desarpton b. Operation PARKING BRAKE (SOME VEHICLE MoveLs) 2a a4 a a a4 22 23 2 2a 2a 2a 2a 2a 24 24 24 24 24 25 26 25 25 25 26 26 2 26 26 24, 2.6, 246, aa, 2a, 2. Dosertion| ». Operation PAN, STRAINER 12. Desorption ». Operation INPUT PRESSURE AND SCAVENGE PUMP 2. Description | », Operation HOUSING, COVERS, 2, Font Cover », Torque Canvorter Housing Main Housing HYDRAULIC SYSTEM (ALL MODELS) 2. System Functions b. System Schematics Fite, Main Pressure Regulator Valve 4. Lockip Ctch Shit Valve © Flow (Lockup Cut) Valve (Models ‘With Non-tocti Lockup) 4. Check Valve (Models With Non-Eeciic Loop) 9 HycrauteRetarder Valve Mods With Retarer) 1h Comarter Pressure Rel Vato (Al Models) 1. Converter Pressure Regulater Valve (dels wih Reterder) |. Lubcation Pressure Regulator Vive (Modes Without Rotarder) 1. Converern Check Vale (Models With Retard) NANUAL-HYDRAULIC CONTROL sysTEM 4 Manual Soletor Vahve 2 Neutra Timmer Valve {6 Inermedte-Range Teer Vive Cop © 2014 Alen Transmison ie. A Rights Raced 2a ar oT ar 27 27 ar 26 26 28 28 28 29 29 29 29 29 29 29 2410 2.40 240 210‘TABLE OF CONTENTS 249, 220, MANUAL-HYDRAULIC CONTROL, SYSTEM CIRCUITS a. Neutral Fst Range Second Range Third Range Fourth Range itn Range Sich Range Reverse MANUAL-ELECTRIC CONTROL, HYORAULIC SYSTEM Reverse Shit Vale Low Range Shit vave Intemedate-Range Shit Valve High Range Shit Vat ‘Solenoid Pressure Regulater Vaio Prot Valve ‘Splter Shit Valve Protecn in the Ever of Elects! Irvamuption 1 Tamer Sytem J Reverse Teinmer eaten te) , Low-Range Trimmer 1 Intermodiate Range Timmer n. Exhaust Regulator Valve 2. Solenoids . Shit Selector Assembly 4. Wiring Hamess MANUAL-ELECTRIC CONTROL HYDRAULIC SYSTEM CIRCUS a. Nowtal » Protoston nthe Event of Electrical Inteuption While Operating in Neutral {Protection in the Event of Electcal Inieuption Wile Operating Forward Ranges 210 at 2 22 aa 22 213 243 243 249 2a 2a asa a9 24 a4 4 214 245. 245. 6 236 216 216 2ar 2ar 2ar 248 218 222, 2a, FirstRange Operation Second Range Operation “Tr-Range Operation Fourth-Range Operon Fit-Range Operation ‘Sa Range Operation Reverse Operation Protection inthe Event of Etctical Interuption Wile Operating in Reverse Protection inthe Event of lctc! Intertion Whe Operating Dusk Elect Equipment ELECTRONIC CONTROL HYDRAULIC SYSTEM AND CIRCUITS (MODELS WITH RIM BOOST). i . Trimmer Sytem Reverse Timmer Low Range Temmer. Intormadat- Range Timmer Spltertigh Timmer SpliterLow Timmer “Tim Boost Valve TORQUE PATHS THROUGH THE TRANSMISSION | Torque Converter Operation . ‘ Loc Operation Neutral Toque Path Fest Rango Torque Path ‘Secont-Range Torque Path ‘Tid Range Torque Path Fourh-Range Torque Path Fit-Range Trque Path ‘Shan Range Torque Path Reverse o Reverse-t Torque Path Reverse2 Torque Path Section 3. PREVENTIVE MAINTENANCE score on Cepyrah ©2014 Aton Trnamison, le. AE gs Reserved 249 219 219 220 220 2a 221 202 222 222 228 223 223 224 224 224 224 225 2a 228 229 290 231 22 233 aAllison 5000 and 6000 Product Families 32 33, 35. 6, 38 ‘TRANSMISSION PROGNOSTICS, PERIODIC INSPECTION AND CARE 3, Eder Clearing nd inspection IMPORTANCE OF PROPER FLUID LeveL ‘3 Transmisslon Pid b, Oil Level Sensor (OLS) “TRANSMISSION FLUID LEVEL CHECK Electron Check Procedure Fld Lovel Chock using Univers ‘Alison DOC® MANUAL FLUIO LEVEL CHECK PROCEDURE ‘COLD CHECK Cold Check Procedure HOT CHECK, | Hot Check Procedure KEEPING FLUID CLEAN FLUID ANALYSIS FLUID RECOMMENDATIONS 8, Recomended Automatic Transmission Faas ». Recommended Viscosty Grade 3-92, FLUID AND FILIEK CHANGE INTERVAL, 8, Transmission Fld Change interval ». Fier Element Change Intervals and Serco 1. Cooler Cec Fite 5-13, FLUID CONTAMINATION aa, a. Water ». Engine Coolant Metal 4, Flush Ol Cooler FLUID ANO FILTER CHANGE PROCEDURE 4 a “4 a 4 32 32 33 o Evy a4 37 37 30 30 38 20 30 40 10 0 ou ou a ou ou 318 345 268. 16 om, a8 38 BREATHER, a8 ‘2, Location and Pupose a1 », Maintenance. S48 (CHECKING CLUTCH PRESSURES. ... 3:18, 1. Flic Temperature Gavge 318 . Checking, Adjusting Main Pressure. S18 {© Checking Lubrication Pressure... 3419, 4. Adjusting Lubrication Pressure (Models ‘winout Petar) 320 , Checking Cowererout Pressure... 9:21 |. Checking Fd Velocity Governor (Pit) Pressure (Models With Ner-Electric Locke) 321 '9. Checking Range and Splitor Céch Pressures 322 “TRANSMISSION STALL TEST AND NEUTRAL COOL-DOWN CHECK aaa a. Purpose. 323 », Stal Testing Preparation 3.23 «, Pererming Transmission Stal Test oa 4. Diving Transmision Stall Test... 3-24 €, Diving Transmission Stal Testing Preperation 324 f. Performing A Diving Trarsmisson Sta Test 925 19 Newtal Coal Down Check Procedre 3:25 hh Transmission Sal Test Resuls.... 3.25 FLUIDLEAK DIAGNOSIS 925 | Finding the Leak 326 1 Powder Method 328 Black Light and Dye Method. 3.26 Possible Pons of Fi Leaks and ‘Their Causes 926 Repair the Leak 327 “NGHT FIT FLANGES AND OIL SEAL MAINTENANCE. sar 4, Removal of Fanges and OW Seal... 927 copy © 201 Alison Tansmissln, Al ts Reseed‘TABLE OF CONTENTS i, Instaltion of Oi Sealand Tight Fit anges. 3.28 920, ON-VEHICLE MAINTENANCE. 329 8. Linkage 229 », Extemal Hydraulic Lines and Cooler, . 328 Adjusting Lockup Speed (Modle Wit Non-Eecic Locke) 30 1. Adjusting Parking Brake 292 32 ©. Determining PTO Backlash Limits... 3:32 ‘TROUBLESHOOTING THE ‘TRANSMISSION 338 {. Belore Removal er Operation oss uring Operation a9 ‘Ater Removal fom Equipment... 3:99, ‘Trouteshootng Table aa ». 4 ectronic Contos Troubleshooting .. 9:94 ‘Section 4. GENERAL OVERHAUL 42, “4 46. INFORMATION SCoPE a ‘TOOLS ANO EQUIPMENT. a 2, General Tools Ifomation “1 Special Toole “1 © Improvised Tools and Equipment... 44 4. Mechanic's Toots and Shop REPLACEMENT PARTS “4 |. Ordering information 44 Part Normaty Replaced at Overhaul. 4-4 © Inspection ana Reuse 44 (CAREFUL HANDLING. 4 (CLEANING AND INSPECTION 44 1. Dit Causes Matton 44 . Cleaning Pare 44 © Cleaning Boarings 4 1. Keeping Bearings Clean 45 © Inspecting Bearings 45 | Inspecting Cast Pats ar Machined ‘Surices 45 4 Inspecting Bushings and Trust Washers Inspecting Seskings and Gaskets... 4-7 | Inspecting Gears 4 1 Inspecting Spinod Pais re 1 Inspecting Threaded Pans 48 1 Inspecting Retaining Rings 48 Inspecting Springs 48 1 Inspecting Catch Plates 48 Inspecting Swaged and nterorence-Ft Pane “ 1 Inspecing Sesing Surfaces “ © Inspecting Blectical Components... 49 46. ASSEMBLY PROCEDURES 410 Pats Lubreston 410 1. Grease Used for Assemtiy 410 {© Sealing Compounds and Nonsolute creases 410 4. Chatchs and Pistons 410 4 Threaded Plugs end Hycraule Fitrge 410 1. Coated Trveaded Fasteners. 42 9 Uprype Seats 412 | Buti Sealinos a9 Bearings 419 47. REMOVING (OR INSTALLING) TRANSMISSION 433 {Drala Fis 419 1b Disconneting Cortrots 419 {© Uncoupling Fram Drvane, Vehicle, ‘Ad Engine a3 4. Removing the Tansmisson au 48, WEARUMITS + 49. SPRING SPECIFICATIONS 4 4-10. TORQUE SPECIFICATIONS. an Copy ©2014 Alen Taaneson oA Rigs Reserve iAllison 5000 and 6000 Product Families 4-11, ENGINE, TRANSMISSION ADAPTATION REQUIREMENTS a |, Measuring Equipment. a » Fiywhee! Housing Pot Bore Diameter 415. e Fhywheo! Housing Bore uncut... 415 4. Fiyhee! Housing Face Squareness.. 445 €. Crankshaft Hub Plot or Adopter Diameter a5 {. Crankshaft Hub Pio or Adapter Conconicty a5 1, Fleplate Bot Hole Fates. 415 h. Torque Converter Axial Location... 445 412, CHECKING FLEXPLATE DRIVE ASSEMBLY 416 4. Flat Inspection 416 Engine Crankshaft End Play 416 FleyplatoAssomblyIntallaton .... 446 CHASSIS ANO DRIVELINE INSPECTION. 416 ‘Section 8, TRANSMISSION DISASSEMBLY 51, SCOPE 54 15:2, GENERAL INFORMATION FOR DISASSEMBLY OF TRANSMISSION... 5-1 2, Proportion fr Diaaesomby Ba b, Removal of Contol Compononts 5+ «6, Disassembly Information 5 4. Ung, Handing 5A 59. DISASSEMBLY OF TRANSMISSION... 5:2 ‘a. Removal of Exterior Components... 52 b, Removal of Torque Converter and Related Components 50 Removing Torqie Convert Elements st 4, Removal of Torque Converter Housing, Retarder Housing, and Related Components ere | Removal of Pump, PTO, and Isler {Separating Converter Housing and Reterder Housing, and Removing Related Parts 9, Disassembly of Retarder Housing, “Turbine Shaft, and Related Parts (Modes win Retard) Disassembly of Converter Housing, ‘Turbine Shat, and Related Pars (Modes wanout Retarsen |. Removal of Transmission Output Components i. Removal of Range Planstares, CChtches, and Related Parts From ‘Gut End of Tranemision Main Housing i. Removal of Splitter Cc and Related ‘Section 6. MODULE REBUILD oa 62, 63, oa ‘SCoPE (GENERAL INFORMATION FOR REBUILD (OF SUBASSEMBLIES PARKING BRAKE ASSEMBLY 2. Dsassombly (Folout 31) Assembly (Folout 31) FLTER ASSEMBLIES 8 Dsassembiy—High-Efclency Fters (Foleo 122) 1b Assemby—High-Efiency Fiters (oidout 122) © Disassombly—Remote Fiter (Foddout 121) Assembly Remote Filer (oidout 1241) MAIN-PRESSURE REGULATOR VALVE BODY ASSEMBLY 4. Disassomby Assembly av Contght © 2014 Maan Tanai, ne Al igs Reserved oa 520 524 sar oo et ot 6 et 62 62 62 62 62 62 62TABLE OF CONTENTS or. 69, o0 on, ona oa, ou, 016, NON-ELECTRIC LOCKUP VALVE BODY ASSEMBLY 63 8. Disassombly (Foldout 13-2) 6s bi, Assembly (Foldout 18-2) 6 [ELECTRIC-CONTROL LOCKUP VALVE. ‘BODY ASSEMBLY oa ‘2, Disassembiy(Fldout 12-1) ea i, Assembly (Fldou 13-1) o4 MAIN-PRESSURE TRANSFER TUBE ASSEMBLY 6s 1. Disassomty 6s . Assembly 65 [MANUAL-HYDRAULIC CONTROL VALVE [BODY ASSEMBLY es 1, Disassembly (Foldout 19) 6s , Assembiy (Fldout 19) or ELECTRICIELECTRONIC-CONTROL \VALVE BODY ASSEMBLY (Models ‘witout Trim Boos) 67 1, Disassembly (Foldout 20 or Foldout21), 6s Assembly (Foldout 20 Faldout21) 6.41 ELECTRONIC-CONTROL VALVE BODY ASSEMBLY (Models With Trim Boost). 645 2. Disassembly (Foldout21) 615, hh Aesemhly (ett 9) a STRAINER ASSEMBLY o19 1. Disassembly (Foldout 2-1) e19 b. Assembly (Folsout 23-1) 19 HYDRAULIC RETARDER CONTROL VALVE BODY ASSEMBLY 620 1. Disassembiy (Fldout 142) 620 1. Assombly (Foldut 14.2) 620 LOCKUP-CLUTCH PISTON REWORK. . 620 2. nepecton 620 be. Repair 620 CONVERTER DRIVE HOUSING ASSEMBLY (Remote Mount Models)... 6.21 66. on, 8. er, 620 on 623, 4 Disassembly (Foldut 8-1) 1 Inspection and Repair (Foldout 8-1) Assembly (Folio 8-1) FLYWHEEL ASSEMBLY (Drect Mount Motes) 1 Disassembly Foldut 8-2) Inspection and Repair (Foliout 8:2) Assembly Folout 82) STATOR ASSEMBLY—TOROUE, CONVERTER 2 Disassembly (Fotdout 9-2) 9. Assembly (Fodout 9:2) TORQUE CONVERTER PUMP ASSEMBLY 1 Disassembly Foliout 92) 2. Assembly Foldout 92) INPUT PRESSURE, SCAVENGE PUMP ASSEMBLY 2 Disassembly (Fotdut 11) 2 Assembly (Fodout 11) TORQUE CONVERTER HOUSING ASSEMBLY 1, Disassembly (Fotdut 10) Assembly (Folout 10) SPLITTER SUN GEAR ASSEMBLY 1. Disassembly (Folout 15-1 or Fotiout 16-2) Assembly (Faldout 15-1 or Fotdout 12) SPLITTER PLANETARY CARRIER ASSEMBLY 8. Disassomiy (Folout 15-2 or Foldout 16:2) b. Assombly (Fekdout 15-2 or Folios 16:2) 'SPLITTER-LOW CLUTCH AND DRUM [ASSEMBLY—M 5600, AND $ 5600 MODELS Copytah ©2014 Aton Trmaison, kr. AE gts Reserved 621 622 ea eas 623 025 623 623 624 624 om om 624 025 625 628 626 ear 627 628 620Allison 5000 and 6000 Product Famili 624 025. 626, ear, 628, 628. eo. os, ex. 1, Dicaceembly (Fldout 15-1) . Assembly (Foldout 15-1) ‘SPLITTER-LOW CLUTCH AND DRUM ‘ASSEMBLY 6600, § 6600 SERIES MODELS 1. Disassembly (Foldout 16-1) ». Assembly (Fokout 16-1) HYDRAULIC RETARDER HOUSING ASSEMBLY ‘4 Disassembly (Folout 14-1) Assembly (Foldut 14-1) ‘OUTPUT DRIVE HOUSING ASSEMBLY 8, Disassembly (Foldout 27) b, Assembly (oldout 27) OUTPUT DRIVE HOUSING. ‘8 Dieassombly (Foout 26) b, Assombly (Foldout 26) BEARING RETAINER ASSEMBLY. 1. Disassembly (Folout 27) 1b Assombly (Folsut 27) (OUTPUT DISCONNECT ASSEMBLY 4. Disassembly (Foldout 29 or Fold 30) 1 Aesembly (Fokdut 20 or Fant 20) OUTPUT DRIVE GEAR ASSEMBLY a. Disassemty. , Assembty ‘OUTPUT IDLER GEAR ASSEMBLY. 2. Disassembly Assembly ‘TRANSFER GEAR HOUSING (OROPEOX) ASSEMBLY ‘. Disassembly Assembly REVERSE-RANGE PLANETARY CARRIER ASSEMBLY 20 630 630 en x2 ox oz x2 622 633 038 63 638 633 639 os 636. 2 Dsaesembly Foldout 25-2) , Resembty (Fodout 25-2) LOW-RANGE PLANETARY CARRIER ASSEMBLY 8. Disassembly (Foliout 25-1) be, Assembly (Folout 25-1) SP-ITTER OUTPUT SHAFT AND COLLECTOR RING ASSEMBLY 8, Disassembly (Fodout 24 and Fldut 25-1) Inspection and Repair (Foldout 25- » Assembly (Fodout 24 and Foldout 25-1) INTERMEDIATE-RANGE PLANETARY CARRIER ASSEMBLY 2. Disassembly (Foldout 24) 1b, Assembly Foidut 24) HIGH-RANGE CLUTCH AND DRUM ASSEMBLY ‘2, Disassombly (Foldut 18) . Ascombly (Foldout 18) TRANSMISSION MAIN HOUSING ASSEMBLY... 1, Disassembly (Folsout 17-1) 1. Aesembly Foldut 17-4) ‘Section 7. TRANSMISSION ASSEMBLY 7 72. 1. ‘S20PE GENERAL INFORMATION FOR FINAL ASSEMBLY “TRANSMISSION ASSEMBLY (AI Nodes) 42 rstaling Spier Ring Gear, Irtemedate- Range Carr ‘Assemby, High-Range Ctch, ‘and inermodite-Range Chtch Conyight © 2014 Alaon Tenens, ne Al igs Reserved ra) 7TABLE OF CONTENTS ». Instating Low-Rango Ring Gear, LowRange Clu, and Reverse Cktch Anchor 18 © Instaling Low-Range and Reverse Planetais and Reverse Chitch 7-8 4. Insaling Output Drive Housing Components (Sight Through Models) 19 ©, stating Transfer Gear Housing Assembly and Rear Gover (Dropbox Models) 740 1 Instating Splitter Output Shah Retaining Ring, Splitter High Cltch 74 9. Instaling Spltter Planeta, Spliter-Low (Chich, and HycaulicRetarder (Models With Retarder) ta 1 Instaing Convertr Housing ‘Compnens 720 |. naling Torue Converter Housing (Medes With Retard) 13 |. stating Spite Planetary, Splter-Low Chich, and Converter Housing (Models ‘wanout Retarder) 724 1. Instating Torque Converter Pum, Stators ra | Instating Torque Convertor “Turbine, Lockup-Clch, and input Components 728 '. nsaling Exterior Components (A Models) 730 1. Power Takeo Gea Backash 738 7-4, INSTALLATION OF CONTROL ‘COMPONENTS: 738 ‘Soction 8. WEAR LIMITS AND SPRING DATA 841. WEAR LIMITS DATA, 8 8. Maxima Variations a Clearing and nepecton 8s 82. SPRINGDATA 26 1. Spring Replacement 86 Inspection 26 Sectien 9. CUSTOMER SERVICE 844. OWNER ASSISTANCE, ot FOLDOUTS 1. M6610, 5 6510 Series Transmission Cross Section 2 W 5800 Seis Cross Section ‘3. W 6600 Series Transmission Cross Section 4. Remote Mount and Drop Box 80016800 Series Cross Secon 5. $861, 5061, 6061 Transmissions — anual Hyéraue Schemate 6. 5861, 5963, 6061, 6962, 062 ransmissions — Elecire-Contol yorause Schematic 7. $968, 6063, M5600, $5600 Series, and 1 6500, $6600 Series (Modale With Tien Boost and Electie Lckip) — Hydrauio Schematic 2-1. Range, Converter rive, ad Front Cover 8.2. Rexplte and Flywheel 8-1, Loc Chen 2-2. Toque Convertor 10. Torque Conver Housing 11. put Pressure and Seavenge Pump 124, Main-Prossure Regulator Valve (Models Win Remote Fiters) 122, Main Pressure Regulator Valve and igh Efiiency Fiore 184, ElcicLocp Valve Body Assembly 182, Nonlctie Lockup Valve Body Assembly 14, HyerauieRetarder and Turbine Output Shaft 142, HyerauieRetardor Conta Vave Assembly 154, SpiterLow Clutch — M600, $ 5600 Series Cent ©2014 Aen Taman, In Al Ripe Reserved aaAlison 5000 and 6000 Product Families 15:2, Splter Planetary and SpitterHgh Ctch M1 5600, § 5600 Series 46-1. Splite-Low Chch —M 8600, $6800 Sores 16-2, Spiter Planetary and Splter-High Ch M6600, S 8600 Series 17-1 Transmssion Housing Without OLS Ready Housing 17-2, Tranamiaslon Housing Wah OLS Ready Housing 18. High-Range Chtcn 19. Manvabiyéralc Conte Valve Assembly 20. Con! Valve Assembly Manual Elctic 21, Electronic Conta Valve Assembly (Models Without Ten Boost) 22 Electron: Conta Vale Assembly Models ah Tein Boost) 23-4. Pan (Straight Though Models) 25:2, Pan (Oropbox Medes) 24. Intermediate Range Panetary and Intermediate Range Clch 25.1. Low-Range Planetary and Low-Range Cuch 252. Reverse Planetary and Reverse Cch 26, Output Dre Housings 27. Output ve Housing and Speedometr ‘Components 28, Transfer Goar Housing, Gers, nd Output Components 29, Transfer Gear Housing, Gears, and Rear Ouuput Disconnects 30. Transfer Gasr Housing, Gears, and Front ‘Output Disconnect 31. Parking rake it Copy © 2014 Aizen Tanai, ne Al Fights Resor‘SECTION 1—GENERAL INFORMATION 444. SCOPE OF MANUAL |& Coverage. Ths Service Manval deserbes the ‘Operation, maintonance, and overhaul procedures for: +H. MS 5620, 8620 (H),(M), (A, and(R) Descriptions ofthe major components ofthe transmissions (rele to Figure 1~1 though Figura 14), the tunetlon and operation ofthe hydraulic syetom, wear mits, and inspection Procedures ae included. Torque specifications are ‘ven wit each assembly stop and on the exploded ‘ow fldouts at the back of this manual. Inston’ Apply generally to al models. Whore procedures ‘vary between modes, netrucons ident spectic ‘model. (ite wore res woe B20 Figure 1-1. Typical 862016620 Series Transmissicn Model With Electronic-Contral ‘Main Valve Body, Trim Boost, and Electric Lockup Copyfah @ 2014 Aan Tanai, Al Fights Reserved “4Allison 000 and 6000 Product Famil eee Figure 1-2 Typical 5620/6620 Series Transmission, Remote Mount—Left Rear View ‘copy ©2014 Aison Tenens, Ie. Al Rights RecordGENERAL INFORMATION Figure 1-3. Typlcal CLT 5620/6620 Sores Trassmission, Direct Mount, With Transfer Gears (Dropbox)—LeftFront View Copy ©2044 Aton Trane, ie. Ags Reserved 1Allison 5000 and 6000 Produ:t Families Figure 1-4, Typical CLT 562016620 Se = Transmission, Direct Mount, With Transfer Goats (Oropbox}—Right-Rear View b. tMlustrations. Ovemnau! procedures are Mustrated mainy by photographs. Line drawings fae use Io saponin elated assenbly procedures; cross sections show torque paths ‘andthe relalonship of assembled paris. Cross ‘sections color-coded hydraulic schematics, and pars exploded views ae on foldouts atthe back ‘0f this manual, The foidouts may be opened for reference whl studying the text Maintenance Information. Each task described in this manual has been succossflly completed by service organizations and individual, Not overy Service organization o individual possesses the ‘required special too, taining, or experience to perform al described tasks. However, any task may be performed ifthe folowing concitons are met +The organization or individual nas he required rood ofthe task Uwoug: = Formal instruction at an Asin ‘Transmission dealer ora istibutor training focity = Onthe;eb instruction by an Alison Transmission dealer or distributor representative = Experiene in performing the task + The work environment i sulable to prevent ‘antamnaton or damage to transmission ste or assombles, + The required tools and fires needed are shown n Secon 4, GENERAL OVERHAUL INFORMATION. + Reasonable and prudent maintenance pactces aro used 14 Copy © 2014 Alon Trnenison, ne Al gts Reserved,GENERAL INFORMATION NOTE: Service organizations and Individuals are encouraged to contact ‘hel local Alison Transmission dealer o ‘stibutor for information and guidance on ny task outned In this manual #2. ‘SUPPLEMENTARY INFORMATION ‘Supplementary information is issued, as required, f any changes occu fer publication ofthis mana (Chock wih your dealer oF detribtor to be eure you have the latest information. 1-3. ORDERING PARTS ‘Transmission Nameplate. The transmission ‘amoplto (refer to Figure 1-5) i located on th "ight sie of he transmission and imprinted with he folowing information: + Model number + Part number (assembly number) + Serial number Use these numbers when ordering replacement pars or requesting service information, Figure 1-5. Transmission Nameplate Parts Catalog. Replacement parts are listed in Parts Calalog PCIBG0EN andthe Parts Catalog on the Alison Transmssion web ste at wwalisntransmission com. D0 not order bythe ‘tem numbers used on disassemtiod views in his ‘manual, Use the pars catalog to determine the ‘correct part rumbor 1-4, DESIGN FEATURES 14. Trnsmission-toEngine Coupling. 1. The diect mounted transmission has a ‘modified SAE #1 mourting face on the ‘converter housing which is bolted tothe engine fywhee! housing. A exible Rwheet ‘isk assombl connects he engine rarkshat ‘phe vansmiesion mput. 2, The remote-mounted transmission has a front ‘over. A customer-elected flange connects fhe engine va acrive sha and universal [pris othe splined hub ofthe converter drive housing 'b, Terque Converter. The fxed-capacity torque convertor i a single stage. polyphase, {hree-sement uni, consisting ofa pump, stator, and turbine. The convetr provides maximum torque ‘when iad conditions demand. Hydraulic Rud for ‘converter charging pressure comes from the sump ‘and is supped by tne pump. ‘& Phnetary Gearing. The planetary gear tain inctudos constant mesh, straight spur goa planetary sels, “he forward sets arranged for averive ‘iroct eve and is called the splitter planetary. The Temaining cots are the intermediate planetary, the low planetary, and the reverse planetary. By the engagement ofthe clutches in various combinations, the planetary sets act singly or together to provide six foward ranges and one or wo reverse ranges. 4, Clutches. The clutches drat the flow of torque ‘through the transmision in accordance wit the range selected by the operator. All clutches are hhydeauicaly apied and cooled by the transmission fd, Al cutches, except the lockup etch, are spring released, The lockup clich is released by hyéraute pressure fom the torque converter. The leckup chute is automatealy agusted to compensate fr wear and no manual adjustment is necassan. ©. Hydraulle System. A common hydraulic systom ‘serves the lorque converte, the hydraulic retarder, land te vansmission. Transmission fad for all hydra operations, lubrication, and cooling comes. ‘rom fe sump and is supplied bythe same purr (foforo Folout 5, Foldout 6, and Foldout 7). Copyright ©2014 Aton Tanerietn I. Al Rs Reserved 16Allison 5000 and 6000 Product Families 1. Power Takeot (PTO). 3. Electical power for actuation of the conta 4. A top mounted PTO gear is available to ‘sydom fs supped bythe equipment electical ‘tive auxin equipmert. The spur gear is Sytem. Elecical components to match the fengine-dven and operates at 1.21 times feqipment system votage (12V or 24V DC) engine speed. The eghtbe mourtng fango fare provided nthe contol system. An intel '8 SAE heavy ‘SFE 9A fuse ie provided in tho selector asrembiy. 2. Aside-nounted PTO is avaiable on he freight si otto torque convert 4. Fo’ models wth lockn-ange, if eecical housing Its riven by @ gear whch rtatos Boveri rerun (ar ve slr ‘1 00 mes engine speed. The eigh-bot iy), the tranamisson wi continue ‘mounting Mange f SAE heavy a to pera inthe ferward range in which ae as wos operating tthe time ofthe electrical 1b Lockup etuiet Intsrupton the electrical interruption occurs in nutay, the transmission will romain in attra: the electical interruption occurs in ‘verse, the transmission wil go ilo neutral 4. Thelockup clutch assembly incies a single clutch plate, a piston, and a backplate. The Intema-splined dutch pate is splined to Wine oe coments urtne, Whon he 5. Fer modes wih loc-in-neutal, if lectrcal ‘ch sapped, the converter turbine and power sintered (ete atone solenid Seecnate noe ead opens en Ereomplty) the wansmisson wl hit Toate 2s unt. Engine powers rami toneuta rom any range in which was {othe tanamission goaing ata 1:1 rao. ‘ogerating. An elcid interruption in Iasae conzs'u cianges secmel tae ‘alcool sraper moses causes the rear cdmmece, transmission lock in neta rom any range. 2 Elecronic-control models are equipped with b, Elestroni-Contro! Shit ‘lectoni-contrl lockup value assem (8) (felerioFoldot 13-1); non-lecrone modeis +» At sletoni, mlctocomputertased I fre eqioped with lockup valve assembly (8) pice ies revered Beet cee a fuerte Podiut 132) ‘and is used inthe 6620 end 6520 models 2, The electronic contol system consis of an “TOM, thrtte poston soures,eutput speed 1-5. SHIFT CONTROL SYSTEMS nso, input speed sensor, turbine speed ‘Sensor, solenadsin the conta vave bodies, 1. The manual-letie system Includes that connect these components. The tote, slectcaly-contoled valve body ascombly postion source, speed sensors, and shit (10) (afer to Foidout 21) onthe transmission, lector transmit formation tothe TCM. The fan operator controted manual shit sector ‘TOM processes ths information nd then land wiring harness, Also included is prossure ‘sends signals o actuate speci solenoids ‘snitch (2) (eter to Foldout 13-2) which local within the coil valve bodes on ‘ctvales @ downshit inhibitor. the Vansmission. The action ofthe solenoids lect hydraulic crus wich intr, contr the upehts, downshifts, and lockup funeions. In adion to cortrofing the operation of ‘he transmission, the electronic contol ‘itor the system for abnormal conditions. “Ihe Universal Alison DOC® is used ding bstallation checkout and troubleshooting, ‘Some OEM components such as the Yehite interface Wiring (VIW) connectors, and VIM so communicate with the TCM. 2. Electromagnetic solenoid valves contol hydraulic cet that shit tho range contol valves, Sic forward ranges, uta, and two reverse ranges are selected manually bythe ‘operate. The eectical orc, established by each positon ofthe operators shit selector estabishes a hydraulic eeuitin the transmission vale body that produces neutral ‘rare nthe range selected 6 ‘Copyiht ©:2014 Alice Tanemstn, ne. Al igs Resoved.GENERAL INFORMATION when an abnormal conaiion is detected the electronic controls ar programmed to automaticaly respond in a manner which is safe forte operator, the equipment, ‘andthe transmission, and to record the proper clagnostic code in momery. When ‘an abnormal conation occurs, the CHECK "TRANS ight on the instrument panel ights up. Refer fo CEC2 Troubleshooting Manual “TSS35SEN, or CECS Troubleshooting Manus ‘TSTSSTEN for iformation on diagnostics, ‘wovbleshoatng, and repair. & Manual-Hydraulle Shit. Some 5620 ‘and 6620 Series models are equpped with ‘marualy-contotied vate body (8) (eer to Foldout 19). The conto valve is connected by ‘mechanical rkage fo he shit sector. Bocause there is no automatic siting in this system, tho perator must move the shit selector lever obtain the desired operating range 1-6. OPTIONS &. Hydraulle Retarder. Tho hydraulic retarder Consists of a rotor, fxed stator vanes, and an operator contd valve, The rotor tures ‘continuously a turbine output shaft speed. However, the retarder functons only when te eaviy around the rotors filed wth transmission fd. The rotor vanes fore the Mid into the pockets between the fixed vanes inthe rote cavily, making it harder for the rotor totum. This slows the transmission output ._ Parking Brake. A two-shoe, expanding parking brake may be mounted athe rear output of he ‘wansmission, {6 Transtor Gears (Oropbox). The ranser gears forthe transmission ult provide a rab of ‘The transfer gear housing provides tanirission ‘output drive at a point 18% inches (470 mm) lower than the transmission input catering. The transmission sump i nigral withthe transfer gear housing (dropbox). The transfer gear housing has ‘utput locations atthe front andor rer. 44. Output Disconnects. Some dropbox models have output disconnects at op rear, bottom rear, ndior bottom fon output locations ‘6. Flanges. Various models uso a vary of input and output anges. 4. Speedometer Drive, For non-electronic ‘made, the speedometer drive i regia, SAE ‘kz Inch avy duty. On staightthrough models, the speedometer drive rato is 0.501. Transfer ‘gear nodels have a speodometor rato of 1:1 For 842016620 models wih CEC2, speedometer Signals aro avaiable rom the evtemorfumished VIM 0" wir 187 from th customer-tunshed VIW-S ‘connector (eer to CEC2 Contels and OF Highway Salos Tech Data Book, SA32Z7EN Section C), NOTE: Do not epic ito the Wansmission harness to se the signal crety tor the speed sensor. The speed sansor signals are ONLY for use bythe TM. 4-7. DIAGNosTICs ‘Before Starting. enti the faut conton and is prebable cause before atomptng to repair the transniasion, CHECK TRANS Light. Continued ituminaton ‘ofthe CHECK TRANS light curing vohicie poration Indicates the TOM has signaled a DTC. A startup, the CHECK TRANS ight briefly iminats, 1-8. Proservation and Storage Storage, New Transmission (Prior to Instafetion Now tansmissions are tested atthe Alison factory ith preservative ol and crained prior to shipment. “The resiaal ol remaining inthe transmission rovdos adequate protection to safely store the \tansmission for up to one year ste indoors In ‘conditons of normal cite, and wih a shipping luge instal) without further trestment b. Preservation Methods. When the transmission iso be stored o o remain Inacthe for an extended period (one or more years), ‘specif preservation methods are recommended to prevent damage due to rust, corosion, and organic ‘copy ©2014 Aeon Taamieson AI Riss Reserves WAllison 5000 and 6000 Product Families rom n the Mle. Preservation methods are thorughlysstibute the fid and to cause resented for storage wth and without transmission lockup operaton fui. 5. Cortinue running the engine st 1500 rpm with the transmission in N (Neutra) unt noma ‘operating temperature i each. ©. Storage, One Yoar—Without Transmission Fu. 4 Drain the transmission fi 2. Spray two ounces (60 milters) of VOI #10 {or equivalent) nto the transmission trough ‘he fl ube 3, Seal al openings and breather with ‘molsture-ro0f tape, 4, Coat all exposed, unpainted surfaces wit preservative grease such as potoatum {(MlL-C-11786, Class 2) 5, acional storage tme is required, remove tape from the fil tube and repeat Steps 2 ough 4 at yearly intra 4. Storage, One Yoar—With Transmission Fluid (WormallyInstaied in the Equipment). 4. Drain the tranamiasion fuld and replace the titer elements (fr to 3-18. FLUID AND FILTER CHANGE PROCEDURE) 6. If sormal operating temperature i ess than 107°C (225°), (rofer to 3-17, ‘TRANSMISSION STALL TEST AND 2. Fil the ranemissin to operating level wth [NEUTRAL COOL-DOWN CHECK) and briefly ‘msde of ane part VCI #10 (or equivalent) to Stall the converter. When the converter out 30 parts transmission fid. Add % teaspoon temperature reaches 225° (107°), stop the ‘of BioborJF®(or equivalent) for every gallon fergine. Do nat exceed 107°C (225°) {@ mifor every 10ers) of transmission ud IAs aaa es Vaaeniolon G Gel toa ‘the gystom taxeh, seal al oparings and the breathes with — — rmostre-proot tape. (ah) NOTE Wien aang nm amour of Coat all exposed, unpainted surfaces with Biobor JF® required, use the toa volume of preservative grate such as petrlatum the systom, not just the quantly requires to (ants-11796, Class 2) filthe vanamission. Include external ines, Soe additonal storage tne is require, epeat ‘Seps 2 trough 8 at yeary intervals; exceph, Its nat necessary to dain the transmission ‘each year Just add VCI #10 and Bicbor JF® (ce equivalents) 3. Run the engine for approximately fve minutes {1 1600 rpm with tho transmission in N (Neutra), 4. For automatie-shit models, shitto D (Orv) 9, Restoring Transmission to Service. ‘and operate the equipment for epproximatoly five minutos ata sufient speed to 4. Remove all tape trom openings and the ‘cause shchvrange lockup operation. For sesliee ‘manda-sit model, operate the equipment 2. Vash of al extemal greaso with mineral {or approximately five minutos a suicient ‘ints. speedto shift through all selector positons fo, the transmission is new, drain he resi ‘reservatve ol Refll the transmission io 8 Copy © 2014 Neon Transmisson, nc A RightsReservedGENERAL INFORMATION the proper lovel with transmission fd (refer to 3-14, FLUID AND FILTER CHANGE PROCEDURE). 4, Ifthe transmission was prepared for ‘storage without uid, dain the residual ‘uid and repace the iter elements. Refi the transmission tothe propor level wih ‘wansmission fd rer to 3-14, FLUID AND FILTER CHANGE PROCEDURE), 5, Ifthe transmission was prepared fr storage th Rud ts not necessary to arin and Fell the transmission with new tanemission hid. Chock fr proper fui evel (oer to 3-5. TRANSMISSION FLUID LEVEL CHECK, ‘A ordain wansmision fds required to ‘oblainthe proper level 1-9, RESTORING TRANSMISSION TO SERVICE ‘8. Transmission Extorir. Wash al external ‘79280 rom the wansmission with mineral sp. ‘Sealed Breather and Openings. Remove all tape trom openings and te bathe {&_New Transmissions. ifthe transmission is ew, drain the resval preservative fd. Refi the transmission to he propr love with an Alison ‘approved wansmission Wid Stored Without Fluld. the ansmission was ‘Prepared for storage without fui, drain the residual uid and replace the ol iter element. Ril he transmission tothe proper level wih an Alison ‘approved transmission fd. ©. ‘Stored With Fluid. f the transmission was Prepared for storage with fi, tis no necessary to drain and rfl he transmission wih new transmission fid. Chock fer proper Midlevel. Add 0 drain transmission fd, as required, to obtain ‘the prope eve 1-10. OPERATING INSTRUCTIONS Operator's Manual. Refer tothe curent ‘Operators Manuals OMISTBEN, OMZOQAEN, oF ‘OM3S40EN fr operating instructions, 4-11, SPECIFICATIONS AND DATA “The sfocieations and data in the following tables apply all models covered by this manual, unless cotharise speciiog ‘Tho maximum input torque and power valves listed in the nput ratings tablos represent net torque and ower as installed (net and exhaust restictons, altemtor charging, cooing fan, power steering pump, AIC compressor, when appicabe) Copyright © 2014 Alon Tension, Inc. A igs Reserve. 19Allison 5000 and 6000 Product Families Ts NOBEL Input Torque, = “ va ere age, | seme oon | on | ams rat ‘et__| Engine Speeds ‘STRAIGHTTHRU MODELS Ful ood Governes Hauling [600 wo as 1 ars | Hestnum 2800 rm Apleatons Jiss7) _|iaro) | asta (2379) ry) __| kur 000 ren SOPeOT WOE tae Spred ine c aS. Aira S80 Hauling [600 rn Tr wats Aoptestons Jiwwry [sion | asta esr) ay Tae WODEL ‘np Power Teput Tore Tete tp Ow “pa (er Tera Spee ia ti) wean) oom 7a oo rat ret | Engine Speeds ‘STRAVGHT-THRU MODELS Fultzes Goemed ‘General [600 roy wars] 775078 | nes 2500 rom ternary casa) esr) __[tartn» _| Mir 1800 Oi iia, | 600 550 avs [1750 | srs | We Speed in Deve ey feet) fe farm) [tarry | Mrmr som = rr) es fas [so Gry |» |azn__ aor aes 750 710 ‘20 zz70 | 3790 (63) (620 faore) is) ‘DROPBOX MODELS ‘Generat [600 = wwe‘ a5 fey fai ease) fizsry [arin 0 5 ‘ars 7s [75 fy ltt) [tase srs) ert +10 Copy © 2014 Alan Transmission, Ine Al Rights ReseedGENERAL INFORMATION aim wooeL Tate ng Power ret Tee a = ee ea wn) wn) a a a mt ‘SRAGHT-THRU MODELS Gener] 600 co a ty feet) fase) fara [arin onFiaa [os 5 aso] eso. [re to, __|weoy [ary |asen [ery Ta Traor 500 7 veo | vas | 320 gm |i) fam fora | ee Tua a 60 0 a cn tenor ear fiat) fase ery tary Ft DROPBOK MODELS General [600 3 a tay) __ ease tarry [aren oFiaa— }00 50 wars [so | a5 tary feet) frase) dzary [iar a6 WOO ipa Taine te Torque Bam) bem) rot_[orose | not _ [ot | spends outra | 7=0 [710 |ason a0. | 799 | engine Speeds Apptatons| (er) | (62) | (3000) [ore Sto) | FultaosCoveras spe0e Fearon 2500 oo tr 900 en tae Sena nee Hin 550 Copyroh ©2044 Alen Tansmisin, e Al Figs Reserved a‘Alison 5000 and 6000 Product Families ware WoOEL Ttne Ings Power Terese te seem) ose | et net_| owe — Genet 700 [HO Fd a fen |e Gor) [rss _| eas'Sene ‘uF | o00 350 72300 4000 Fem 2500 rp fer __| ea ro [teres Metra 20 0m Tveran | 008 78 sono | smo. |e Sena nr fev [tren [ern faery, | aon) |r) | 850 2 fanine tone Since natncer [mo [so mo [a0 nto fier ase fens Saas NOBEL Tapa Taine ac Xoroe wen) wn en) nt_| ger” | noe _| nee somnts Gaon 70 || 70760 | Engi Spee Recaan| son) em) [am core) fisamy | Fated etna Spo fons e No 909 2 Ido Speedin bce iS ‘orrina [mo so [ass 00a fry |en [erm |e out Cine ohon vowed fm rt oa) Cutt orm pion) can nan vowed fom ra) mounrne: oreet yea asin SESE ou to srovrina os reat Remete “rons ort 0 SAE enti pas at TORQUE CONVERTER: pe sageoe, ‘rol obese sa Tore Fale ale 1-1 12 Capt © 201 Mo Taare, eis ResoGENERAL INFORMATION ‘Table 1-1. Torque Converters ae20, ‘ial Torque Ratio e620 Ze: 2m 2ar206F ar res ani er™ Reta Rtaraor Come Lockur cuuTeH: ‘somatic a ranges, of Suomi ranges excopt owas and reverse GEAR DATA: Range ang Spor Constant mesh, spusype panatary Transfer Gearing Contant mesh nthe RANGE OPERATION RATIOS (ALL MODELS)” Fst Range 4001 Second Range 2681 ‘Ths Range 20m Fourth Range 1261 Fit Range 1.01 ‘Sith Range osrs Rewrne 15:15: end 34641 Transfer Gears (optox models) 10021 RANGE CLUTCHES: itlatenyrauic actuated, Sancta hice POWER TAKEOFF (TOP AND SIDE): Mounting Flange Two, SAE 8-0 Henny duly Rating (ther o bath eatin) Ieermitent-200 np (149 7) (Contnuous- 1251p (03K) ato Copy ©2014 lleon Trane, ns AL Fights Resared 13Allison 5000 and 6000 Product Families Speedomatr Drive: Size ato Parking Brake Type Rating see HYDRAULIC SYSTEM: ‘sume Input Pressure and Scavonge Pup Ftd Type PARAMETER value Teanamision Ony 5000-Series Medes 0372) (6000-Seres Medes 63,72) Dropbox ony 5000 Series 4982) Fors Converter ut Pres: Reverse, 1,2,3,4,5.8 unr ar (Quarts) iter (Quer) Liters (Quarts) Top mounted 25 degree pressure ang, pen, 38 tea ‘Semounied—25 degree pressure angle th, 48 {etn SAE ahem ty Suaightinougn moses sor “ansier gear modal: 1.01 erat expanding shoo 20000. ines (101681) SUSI7 b 00 N) lever pu” 2x5 ince (2053 127 mm) eto Poste deplocement spur ype Refer to 3-11, FLUID RECOMMENDATIONS FLUID TYPE: Use TranSynd® RO or © ‘FES-409opproved Att of approved TES 238 fads or OF Highway se 1 fund on mo TES439 ius Uist ont Ason Tlanamation wots, otor (Si) 10-18-98, STransmisn Pd and itor ‘Saves Recormendvns” Ful ow, elacsabe ‘meu high eicency 170-180 ai (1172-12753) 31500 pm, ouput stated, ‘ranges and chip Fultroto, poral operating ‘put speed. 20-05 pa aor-aaa Ke) 4 Copy © 2014 Alon Transition, nA Figs Reseed.GENERAL INFORMATION Lutron Pressure ovoree, 1.2, 3,4.5.6 Neutat Models With Ratader ‘TEMPERATURE (ALL MCDELS) PARAMETER ‘VALUE Mmm Star-Up. Type TES-430, OW30 Fis 90 (22) man Sta-Up, Type TES-430, 15040 Fit 86) ‘Sump, Miri Continuous 8 (80) ‘Sum, Maximum Contowous 121 950) ‘Sum, Maxirusn triton 13575) CConver-Out, Maximum Contino 135.275) Convert Out, Maximum Intra 149 600) -Retarde-Ou Masini triton 185 30) NOTE: Vauosin U.S. nts shown in perentneses () aro for ‘eference puposos on Conversions between Met and (U.S unt ee not neeeanray equ HYDRAULIC RETARDER: ‘Maximum Estimated Absorpton Capacty at 2100 rpm Rotor Speed 8 1500 pm input sped, ouput stated, models witout "ela 20 psi (138 KP) Ful toto, cutpt stated: 30 (207 iba) aint provided unr Degrees © (DogoesF) Degrees © Depees F) Degrees © (Degrees F) Degrees © (Degrees F) Degrees © (Dogees F) Degrees © (Dogeos F) Degrees © (Cameos F) Degrees (Dagees F) 00 447 HH) capi yr es ORY WEIGHTS: ‘TRANSMISSION CONFIGURATION vaLwe unr 5000 and 6000 Series Mado ‘Seaahi-TheuTransmeson (500-Serie) an p20) (puna) ‘Sigh-TheuTransmesen (800-Serie) 10252280) 9 (ounes) ‘repo Tanemision (5600-Seres ony) 12472780) a (pounes) Top Engne-Dven PTO Drive Gaar Option 4@ (pounds) Retarser Option | 75185) a (ound) Park rake 27@) (pounds) emt Mount Proviion 25) a (pounds) Range opration rato does ntinelu orgs conver “Manacrers ang foun foumishad)conston “Daehn nce hove rings 1-42, ELECTROMAGNETIC/RADIO ‘ther dlectrnicsystoms. Alison Transmission’ FREQUENCY INTERFERENCE ‘lectrenctrensmision controls comply wth Feder Communicators Commission (FCC) regulations [All electrical and electronic systems generate and cher guidelines concering emitted radio electromagnetic folds that can interfere wih frequency interorence for transportation electronics, ‘Copy © 2014 Alcon Tanankslon, ne Al Fights RaresAllison 5000 and 6000 Produ:t Families ‘Some radiotelephone or two-way communications radios (fand-moble radio), or the manner in which they aro installed, can be effaced by other vehicle ‘components or adversely affect vehicle operation, Manufacturers and installers of Electromagnetic Interference EMIYRado Frequency interference (RE) emiting equipment are responsible for ‘adhering o FCC regulations and other guidlines ‘oncoming emitted radio trequency interference for ‘tansportationeectonics. Ratio or cher two-way communication antenna, power, or ground leads near the ansmission wing hares, control Sevices, or power leds may create or be subject {0 EM Ror to the latest revision of the Alison ‘Troubleshooting Manual for cetaied instructions regarding EMI probioms. 1-13, WELDING ON VEHICLE ‘Observe the following precautions when welding ‘on the vehi: + Disconnect the wing hamesses fom the Tem, + Disconnect the TEM power and ground ‘ruts rom the battery, and any electronic ‘contol ground wires connected othe frame or chas + Do not connect welding cables to electronic contol components, + Do mot weld on electronic contol components. + Cover secronic contol components nd ‘wing to protect ter ro ot sath, te 1-14, PAINTING ON VEHICLE ‘8, ELECTROSTATIC PAINTING. Ifthe vehicle ‘chasis or body is painiod using an electrostatic panting process, electrical voltage must not be discharged through the TOM. To provent ‘his possi, Alison recommends instaling ‘the TCM after the electrostatic paint process is complote the TCM is installed prior to electrostatic Painting, make sure: + the TOM isnot painted + the elements being painted are propery fan continuously grounded during the entre ping process. oe en ‘aeponsibi for TCM damage resulting from improper rounding during elecvostaic ining of he vehicle. During dectrostate paining, the pain opts rocoWve an electrostatic charge atacing them tothe ‘rounded surfaces. Voltages at the spray gun can txceed several thousand vats. The charge which bulls wo on an impropety grounded chassis or ‘ody canbe discharged trough the TCM, resuting in damage to the TCM. 'b, PAINTING OF TRANSMISSION CONTROL COMPONENTS. While t may be desrable to paint ‘chassis mounted campenents fo enhance the ‘vera ehicle appearance andlor provide corrosion protectin, the Wansmission control components ‘must nt be painted. Paintng transmission control {components can: + compromise the integrity of connectors and tannector eal. + redyes thermal conduetity fom inside the ‘TEM to ambient a + cover labels of other identification, hindering the press to sence these components 4-15, ENVIRONMENT ‘Alison Transmission designed the Allon conte ‘and components to operate In narmal vehici ca lane chaseis envronments. The Alison conto {and components can withstand moisture, cect Tight, teat, and shock loads. The TCM, Alison Shi selecors and ther connectors are sealed, but fare no considered immersbe. nstlaton ofthe Alison conto and components must meet the ‘environmental requrements in Alison Electronic ‘Contrés Daa. naditon, mount the Alison contros ‘and cemponents away fom direct exposure to toad hazards and weather In order to moet the temperature is sted in AlisonEletrnic Controls Daa, alow for toe air movement around each ‘compenent. The a movement isipaes heat away 148 Copy © 2014 Alison Tranamion, re. Al igh Resorvod